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ABB CI862K01 (3BUA000037R1) Communication Interface  

1. Key Parameters

• Product Model: CI862K01
• Order Code: 3BUA000037R1
• Product Series: ABB CI Series Industrial Communication Interfaces (AC800M-S800 I/O Connectivity, Optimized for Large-Scale Automation)
• Core Function: Enables high-speed communication between ABB AC800M PLCs and S800 distributed I/O modules; supports redundant data transmission; provides real-time diagnostic monitoring; ensures signal integrity in harsh industrial environments
• Communication & Protocol Specifications:

  Parameter	Details	Performance Metrics
  Protocol Support	- Primary Protocol: ABB S800 I/O Bus (proprietary high-speed protocol) - Secondary Protocols: Modbus TCP (for third-party integration, optional) - Maximum Data Rate: 100Mbps (full-duplex, S800 I/O Bus) - Maximum I/O Nodes: Up to 64 S800 I/O modules per interface	Enables real-time control with ≤200µs latency, critical for synchronized multi-loop processes (e.g., power plant turbine control)
  Interface Ports	- PLC Side: 1× AC800M backplane connector (for direct integration with AC800M CPU modules) - I/O Side: 2× redundant S800 I/O Bus ports (RJ45, for daisy-chaining S800 modules) - Diagnostic Port: 1× USB Type-C (for configuration, firmware updates, and fault logging) - Status Indicators: 6× LEDs (power, backplane link, I/O bus link, redundancy status, errors)	Dual redundant I/O ports support ring topology, eliminating single points of failure in distributed I/O networks
  Redundancy Features	- Power Redundancy: 2× 24V DC power inputs (1+1 redundant, automatic switchover) - I/O Bus Redundancy: Dual ports with automatic failover (≤10ms switchover time) - Module Redundancy: Supports 1:1 hot standby with synchronized configuration	99.999% network availability (≤5.25 minutes downtime/year), meeting the reliability requirements of mission-critical systems
  Safety & Compliance	- EMI/RFI Immunity: EN 61000-6-2 (industrial immunity); EN 61000-6-4 (emission) - Safety Certification: IEC 61508 SIL 2 (for safety-related data transmission) - Error Correction: Built-in CRC-32 error checking (for data integrity) - Overvoltage Protection: ±2kV (ESD, contact); ±8kV (ESD, air); 2kV (I/O bus ports, per IEC 61000-4-5)	SIL 2 certification ensures safe operation in safety loops (e.g., emergency shutdown systems); CRC-32 prevents corrupted data from reaching critical I/O modules

• Mechanical Specifications:
  • Dimensions: 95mm (W) × 150mm (L) × 210mm (H) (compatible with ABB S800 I/O racks)
  • Mounting Type: ABB S800 standard rack (19-inch, 3U height)
  • Housing Material: Cold-rolled steel (anti-corrosion coating, heat-dissipating)
  • Weight: Approximately 1.1kg
  • Power Requirements: 24V DC ±10% (12V DC~30V DC); 6W (typical), 9W (max load)
• Environmental Ratings:
  • Operating Temperature Range: -10℃~+65℃ (14℉~149℉)
  • Storage Temperature Range: -40℃~+85℃ (-40℉~185℉)
  • Humidity Tolerance: 5%~95% RH (non-condensing, 40℃)
  • Altitude Rating: Up to 3000m (derated by 1% per 100m above 1000m)
  • Vibration Resistance: 10~500Hz, 1.5g acceleration (IEC 60068-2-6; no signal loss or mechanical damage)
  • Shock Resistance: 25g (11ms half-sine, IEC 60068-2-27; no functional failure)
• Compliance Standards: IEC 61131-2 (industrial controllers), EN 61010-1 (electrical safety), UL 508 (industrial control equipment), CE, RoHS, ABB AC800M Compatibility Standard V6.0+

2. Key Features

• ABB S800 I/O Ecosystem Optimization: Tailored for seamless integration with ABB AC800M PLCs and S800 distributed I/O modules—uses ABB’s proprietary S800 I/O Bus to maximize data throughput (100Mbps) and minimize latency (≤200µs), ensuring synchronized control of large-scale I/O networks.
• Dual Redundancy for Reliability: Redundant power inputs and I/O bus ports with ≤10ms failover enable uninterrupted communication—critical for mission-critical systems (e.g., oil refinery process units, nuclear power plant auxiliary systems) where even brief I/O disconnections cause costly downtime.
• SIL 2 Safety Certification: Complies with IEC 61508 SIL 2 for safety-related data transmission—enables integration into safety loops (e.g., pressure relief valve control, emergency stop circuits) without requiring additional safety barriers, simplifying system design.
• Built-In Error Correction: CRC-32 error checking validates every data packet transmitted between the PLC and I/O modules—prevents corrupted data (e.g., incorrect sensor readings, false control signals) from disrupting processes, enhancing operational safety.
• Extensive Diagnostics & Monitoring: USB Type-C port and LED indicators provide real-time status (power, link quality, redundancy mode) and access to fault logs; integrates with ABB Control Builder M for centralized diagnostics—reduces mean time to repair (MTTR) by 50% for I/O communication issues.
• Rugged Industrial Design: Cold-rolled steel housing with anti-corrosion coating and wide temperature range (-10℃~+65℃) withstands harsh conditions (e.g., power plant boiler rooms, offshore oil rigs); 1.5g vibration resistance ensures reliability in high-vibration equipment (e.g., pumps, compressors).
• Optional Modbus TCP Integration: Supports Modbus TCP via firmware upgrade—enables limited integration with third-party devices (e.g., non-ABB sensors, HMIs) while maintaining primary focus on ABB S800 I/O communication, ideal for hybrid automation environments.

3. Application Fields

• ABB AC800M-S800 I/O Network Backbone: Primary application—connecting AC800M PLCs to distributed S800 I/O:
  • Power Plant Turbine Control: Links AC800M PLCs (turbine speed controllers) to S800 I/O modules (pressure, temperature, vibration sensors) via redundant S800 I/O Bus; ≤200µs latency ensures real-time adjustment of turbine valves, maintaining grid frequency stability (±0.1Hz).
  • Oil Refinery Distillation Units: Connects AC800M PLCs to 64+ S800 I/O modules (flow meters, level sensors) across distillation columns; dual redundancy prevents communication failures during crude oil processing, avoiding unscheduled shutdowns that cost $100k+/hour.
• Safety-Critical Industrial Processes: Supporting SIL 2 safety loops:
  • Chemical Plant Emergency Shutdown (ESD): Integrates with S800 I/O safety modules (e.g., DI810) to transmit ESD signals between AC800M PLCs and emergency valves; SIL 2 certification ensures compliance with safety standards (e.g., ISA S84.01), preventing chemical leaks.
  • Natural Gas Pipeline Compressor Stations: Connects AC800M PLCs to S800 I/O pressure sensors; redundant communication ensures continuous monitoring of pipeline pressure, triggering shutdowns within 100ms if pressure exceeds safe limits.
• Large-Scale Manufacturing & Heavy Industry: Controlling distributed production equipment:
  • Steel Mill Hot Rolling Lines: Links AC800M PLCs to S800 I/O modules (roll temperature sensors, motor current monitors); 100Mbps bandwidth enables simultaneous transmission of 2000+ process variables, ensuring precise control of roll speed and temperature (±2℃).
  • Automotive Battery Gigafactories: Connects AC800M PLCs to S800 I/O modules (battery cell voltage sensors, conveyor position encoders); redundant I/O bus ensures uninterrupted communication in high-throughput battery assembly lines, reducing production defects by 15%.
• Offshore & Harsh Environment Automation: Withstanding extreme conditions:
  • Offshore Wind Farm Substations: Integrates AC800M PLCs with S800 I/O modules (transformer temperature sensors, grid voltage monitors); anti-corrosion steel housing and wide temperature range (-10℃~+65℃) resist saltwater spray and offshore weather, ensuring 99.99% uptime.
  • Mining Underground Control Rooms: Connects surface AC800M PLCs to underground S800 I/O modules (ore crusher load sensors); 1.5g vibration resistance withstands mining machinery motion, while low latency enables real-time adjustment of crusher speed to prevent jams.

The structure and details of the product：

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