ABB CI857 communication interface module

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ABB CI857 Communication Interface Module

Product Description

Key Specs

• System Compatibility:
  Exclusive to ABB AC 800M DCS (all CPU models: PM851, PM864, PM866) 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 (v6.1+) for configuration, diagnostics, and network management.
• EtherNet/IP Performance:

  Parameter	Specification
  Protocol Compliance	EtherNet/IP (ODVA ENET-IP-1.0), CIP (Common Industrial Protocol)
  Operation Modes	EtherNet/IP Scanner (Master: manages up to 64 EtherNet/IP adapters) / Adapter (Slave: for controller-to-controller communication)
  Network Speed	10/100/1000 Mbps (auto-negotiation, full-duplex); supports Gigabit Ethernet for high-bandwidth tasks
  Data Transfer Modes	Cyclic (I/O data, fixed interval) / Acyclic (configuration, fault logs, CIP messaging)
  Maximum I/O Data Size	4096 bytes (input) / 4096 bytes (output) per scanner instance

• Electrical & Isolation:
  • Isolation Ratings: Ethernet port to CEX bus — 2.5kV AC (1min); power circuit to signal circuit — 1kV AC (1min) — prevents ground loops and EMI interference from industrial wiring.
  • Network Protection: Built-in surge protection (IEC 61000-4-5: ±2kV contact, ±4kV air) for Ethernet ports—guards against voltage transients from industrial equipment (e.g., motor starters).
  • Power Supply: Takes 24V DC from the AC 800M/Advant OCS backplane (via CEX bus); power consumption ≤5W (active mode, Gigabit speed).
• Mechanical & Environmental:
  • Dimensions (W×H×D): 160mm×130mm×220mm (19-inch rack-mounted, matches AC 800M module footprint); weight ~1.2kg.
  • 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: ODVA EtherNet/IP Certification, IEC 61131-2 (industrial safety), EN 61000-6-2 (EMC immunity), UL 508 (industrial control), and IEEE 802.3 (Ethernet standard).

Core Functions

1. EtherNet/IP Scanner & Adapter Operation
   • Adapts to diverse network architectures to meet application needs:
     • Scanner (Master) Mode: Acts as the central manager of the EtherNet/IP network, controlling up to 64 EtherNet/IP adapters (e.g., Rockwell Allen-Bradley 1756 I/O modules, ABB ACS880 VFDs, Schneider Modicon M262 PLCs). It schedules cyclic I/O data exchange (e.g., VFD speed setpoints, sensor readings) and handles acyclic CIP messaging (e.g., device configuration, fault log retrieval)—critical for large-scale automated systems (e.g., an automotive assembly line with 50+ robotic workcells).
     • Adapter (Slave) Mode: Enables peer-to-peer communication between two AC 800M controllers (e.g., "Controller A (Scanner) ↔ CI857 (Adapter) ↔ Controller B") for cross-DCS data sharing. For example, it can transmit batch recipe data from a process controller to a packaging line controller, ensuring synchronized production.
2. High-Speed Cyclic & Acyclic Data Transfer
   • Optimizes data flow for both time-critical and non-time-critical tasks:
     • Cyclic I/O Data Transfer: Transmits real-time process data (e.g., 4-20mA pressure readings, digital valve status) at configurable intervals (1ms~1s). At Gigabit speed, it achieves <1ms latency for cyclic data—essential for dynamic control (e.g., adjusting a filling machine’s flow rate based on real-time level feedback).
     • Acyclic CIP Messaging: Handles non-urgent data on demand, including:
       • Device configuration (e.g., updating a VFD’s overcurrent limit via CIP Class 3 messaging).
       • Fault diagnostics (e.g., retrieving a remote I/O module’s "short-circuit" fault code with timestamp).
       • CIP Sync (optional): Supports IEEE 1588 Precision Time Protocol (PTP) for multi-axis synchronization (e.g., coordinating robotic arms in a pick-and-place system with ±1µs time accuracy).
3. Comprehensive Network Diagnostics
   • Enables proactive monitoring and rapid troubleshooting of the EtherNet/IP network:
     • LED Status Indicators:
       • Green "Link/Activity" LED (solid = Ethernet link established; flashing = data transmission).
       • Yellow "Adapter Fault" LED (ON = one or more EtherNet/IP adapters disconnected/faulty).
       • Red "Module Fault" LED (ON = power loss, CEX bus failure, or internal hardware error).
     • Diagnostic Data to Controller: Sends detailed network health data to the AC 800M via the CEX bus, including:
       • Adapter connection status (e.g., "Adapter 17: IP 192.168.1.50 Disconnected").
       • Ethernet error statistics (e.g., "15 CRC errors, 3 collision errors" — indicating wiring or switch issues).
       • I/O data integrity checks (e.g., "Input Data Mismatch for Adapter 8" — alerting to corrupted sensor data).
4. Seamless Integration with AC 800M Control Logic
   • Simplifies system development and reduces commissioning time:
     • Automatic Data Mapping: Control Builder M automatically maps EtherNet/IP I/O data (e.g., a VFD’s speed feedback) to the AC 800M controller’s memory addresses—no manual code writing required for basic cyclic data exchange.
     • Pre-Built CIP Function Blocks: Provides IEC 61131-3 function blocks (e.g., "ENIP_Scanner_Start", "CIP_Message_Send") for advanced operations (e.g., triggering an acyclic read of a device’s serial number, stopping cyclic data transfer for maintenance).
     • Configuration Backup/Restore: Saves EtherNet/IP network settings (IP addresses, adapter lists, data mappings) to the controller’s Flash memory or external USB drive—enabling quick replication across multiple CI857 modules (e.g., 10 identical food packaging lines).

Core Advantages

1. Multi-Vendor EtherNet/IP Compatibility
   ODVA-certified, it works seamlessly with all EtherNet/IP-compliant devices (Rockwell, Schneider, ABB, Siemens) — eliminating vendor lock-in and enabling flexible system expansion (e.g., adding a new third-party VFD to an existing network without replacing the interface).
2. Gigabit Speed for High-Bandwidth Tasks
   1000 Mbps Ethernet support handles large-volume data (e.g., 4096-byte I/O payloads, CIP Sync time data) without latency—outperforming 100 Mbps EtherNet/IP modules (common in legacy systems) for high-density I/O or multi-axis synchronization.
3. Robust Industrial Design
   2.5kV isolation, surge protection, and wide temperature range ensure reliability in harsh environments (e.g., automotive factories with welding EMI, petrochemical plants with dust) — minimizing unplanned downtime.
4. Simplified Safety & Maintenance
   Built-in diagnostics and LED indicators reduce troubleshooting time (e.g., identifying a disconnected adapter in 2 minutes vs. 30 minutes with non-diagnostic modules). CEX bus power eliminates external wiring, reducing installation complexity.

Applications

1. Automotive Assembly Line Control
   • Used in an AC 800M DCS for a car chassis assembly line: Operates as an EtherNet/IP Scanner to control 40 adapters (robotic I/O modules, conveyor VFDs, welders). Cyclic data transfer (1ms interval) synchronizes robot arm movements with conveyor speed, while CIP Sync ensures ±1µs time alignment for precise welding. Surge protection guards against EMI from welding equipment.
2. Food & Beverage Packaging
   • Integrates with Advant OCS in a beverage bottling plant: Acts as a Scanner to manage 25 adapters (fill level sensors, capping machine VFDs, label printers). Cyclic data (50ms interval) adjusts fill volume based on real-time sensor feedback, while acyclic messaging retrieves VFD fault logs for predictive maintenance. IP20 protection and wide temperature range suit clean, temperature-controlled environments.
3. Petrochemical Pump VFD Coordination
   • Controls 30 ABB ACS880 VFDs (EtherNet/IP adapters) in a crude oil pipeline pump station: Cyclic data (100ms interval) sends speed setpoints to VFDs and receives current feedback, ensuring stable pipeline pressure. Acyclic messaging updates VFD overcurrent limits remotely, avoiding on-site visits to hazardous areas.
4. Water Treatment Plant I/O Integration
   • Connects an AC 800M controller to 50 Rockwell 1794 remote I/O modules (EtherNet/IP adapters) in a municipal water plant: Maps sensor data (pH levels, chlorine dosage) via cyclic transfer for PID control, and uses acyclic CIP messages to reset tripped I/O modules—reducing operator site visits to remote pump stations.

Precautions

1. Compatibility Check
   • Confirm use with ABB AC 800M/Advant OCS—incompatible with ABB low-voltage PLCs (e.g., AC500) or third-party DCS (e.g., Emerson DeltaV) due to CEX bus and Control Builder M dependencies. Verify Control Builder M is v6.1+ to support Gigabit speed and CIP Sync.
2. Network Setup Guidelines
   • Use industrial-grade Cat5e/Cat6 shielded twisted-pair cables (impedance 100Ω ±20%) for Ethernet wiring; ground the shield at both ends to suppress EMI.
   • Assign unique IP addresses to the CI857 and all adapters (avoid duplicates); use a dedicated industrial Ethernet switch (e.g., ABB ES800) for the network—shared office switches cause latency and packet loss.
   • For CIP Sync, ensure all devices (CI857, adapters, switch) support IEEE 1588 PTP—mixing non-PTP devices breaks time synchronization.
3. Scanner Load Management
   • Limit the number of adapters to 64 (EtherNet/IP maximum) — exceeding this causes network overload and increased cyclic latency. For larger networks, use multiple CI857 modules (one per subnet).
   • Keep cyclic I/O data size ≤4096 bytes per scanner—larger payloads require fragmentation, slowing down data transfer.
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.
   • Use anti-static gloves and a grounded workbench—ESD can damage the module’s Gigabit Ethernet chip, leading to intermittent link failures.
5. Environmental Protection
   • Operate within -10°C~+50°C—temperatures above 50°C reduce Ethernet chip performance; below -10°C, the module may fail to establish a Gigabit link.
   • Ensure the control cabinet has adequate cooling (airflow ≥0.5m/s) — high load (64 adapters, Gigabit speed) increases module temperature, shortening component lifespan.
6. Genuine Replacement
   • Use only ABB-genuine CI857 modules—counterfeit units lack ODVA certification and surge protection, leading to network instability (e.g., random adapter disconnections) or damage to EtherNet/IP devices (e.g., overvoltage from faulty Ethernet ports).
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