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ABB CI930F (Order Code: 3BDH001010R0001) Communication Interface Module  

1. Key Parameters

• Product Model: CI930F
• Order Code/Part Number: 3BDH001010R0001 (unique identifier for procurement and AC 800M compatibility verification)
• Product Series: ABB AC 800M DCS Multi-Protocol Communication Interface Modules
• Core Function: Acts as a protocol gateway between AC 800M controllers and external systems; enables bidirectional data transfer with legacy devices, third-party DCS/PLCs, and remote I/O networks
• Communication Specifications:
  • Supported Protocols:
    • Industrial Ethernet: Modbus-TCP, Ethernet/IP (client/server), PROFINET IO (controller/device)
    • Serial: Modbus-RTU (RS-485/RS-232), DNP3.0 (serial), IEC 60870-5-101/103 (serial)
    • Fieldbus: PROFIBUS DP (master/slave)
  • Physical Interfaces:
    • Ethernet: 2× 10/100/1000Base-TX (RJ45; supports copper cabling)
    • Serial: 2× RS-485/RS-232 (selectable via DIP switch; 9-pin D-sub)
    • PROFIBUS DP: 1× 9-pin D-sub (male; with built-in 150Ω terminator)
  • Data Transfer Rates:
    • Ethernet: Up to 1Gbps (full-duplex)
    • Serial: Up to 115.2kbps
    • PROFIBUS DP: Up to 12Mbps
  • Redundancy Support:
    • Network: MRP/PRP (Ethernet); PROFIBUS DP redundant segments
    • Power: Compatible with AC 800M redundant power supplies
  • Maximum Connections: 256 concurrent TCP/IP connections (Ethernet); 32 serial nodes; 126 PROFIBUS DP devices
• Electrical Specifications:
  • Power Supply (Backplane): 5V DC (from AC 800M rack; typical current: 1.0A; max current: 1.5A)
  • Power Consumption: ≤7.5W (total, including all interfaces)
  • Isolation:
    • Ethernet: 1kVrms (port to backplane)
    • Serial/PROFIBUS: 2.5kVrms (port to backplane; port to port)
  • Surge Protection: IEC 61000-4-5 (±2kV contact; ±4kV air discharge for all ports)
• Mechanical Specifications:
  • Housing Type: Metal-reinforced flame-retardant plastic (UL94 V-0; EMI shielding + mechanical durability)
  • Dimensions (W×H×D): 50mm × 100mm × 160mm (2-module width; fits AC 800M standard racks)
  • Mounting: Rack-mounted (tool-less snap-in; aligns with AC 800M backplane connectors)
  • Weight: Approximately 350g
  • LED Indicators:
    • Power (PWR): Green (powered on); Red (power fault)
    • Backplane (BUS): Green (PRONETA bus normal); Red (bus fault)
    • Ethernet 1/2 (ETH1/ETH2): Green (link active); Blinking Green (data transmission); Red (link fault)
    • Serial 1/2 (SER1/SER2): Green (link active); Blinking Green (data transmission); Red (fault)
    • PROFIBUS DP (DP): Green (segment active); Blinking Green (data transmission); Red (fault)
    • Redundancy (RED): Green (redundancy active); Amber (failover); Red (redundancy fault)
• Environmental Ratings:
  • Operating Temperature Range: -25℃~+70℃ (-13℉~158℉)
  • Storage Temperature Range: -40℃~+85℃ (-40℉~185℉)
  • Humidity Tolerance: ≤95% RH (non-condensing, 40℃)
  • Vibration Resistance: 10~500Hz, 2g acceleration (IEC 60068-2-6; no communication loss)
  • Shock Resistance: 30g acceleration (11ms duration, IEC 60068-2-27; maintains port integrity)
• Compliance Standards: IEEE 802.3, EN 50170 (PROFIBUS), IEC 60870-5, UL 508, CE, RoHS

2. Key Features

• Multi-Protocol Gateway Capability: Supports Ethernet, serial, and fieldbus protocols in a single module, eliminating the need for multiple dedicated interfaces (e.g., separate Modbus and PROFIBUS modules)—reducing rack space and integration complexity.
• Gigabit Ethernet Performance: 1Gbps Ethernet ports enable high-bandwidth data exchange (e.g., large batch recipes, process historians) and support network redundancy (MRP/PRP) for <50ms failover in critical applications.
• High Isolation for Legacy Devices: 2.5kVrms isolation on serial/PROFIBUS ports protects AC 800M controllers from ground loops or voltage spikes common in legacy industrial systems (e.g., 1990s-era DCS with ungrounded circuits).
• Seamless AC 800M Integration: Configured via ABB Control Builder M software; automatically maps external device data to AC 800M process variables (no custom drivers or script writing required).
• Scalable Device Connectivity: Supports 256 Ethernet connections, 32 serial nodes, and 126 PROFIBUS devices—ideal for large-scale integration (e.g., connecting AC 800M to a plant-wide PROFIBUS network of sensors and drives).
• Industrial-Grade Reliability: Metal-reinforced housing, wide temperature range, and surge protection ensure operation in harsh environments (e.g., offshore platforms, chemical reactors, steel mills).
• Legacy System Modernization: Enables AC 800M DCS to integrate with aging equipment (e.g., Modbus-RTU flow meters, IEC 60870-5 telemetry devices) without replacing functional legacy hardware—reducing upgrade costs.

3. Application Fields

• AC 800M DCS Multi-System Integration: Primary application—connects AC 800M to diverse external systems in:
  • Oil & Gas Refineries: Links AC 800M to third-party turbine control systems (via Ethernet/IP) and legacy tank level sensors (via Modbus-RTU).
  • Power Plants: Integrates with boiler control systems (PROFINET) and grid telemetry devices (IEC 60870-5-101).
  • Chemical Plants: Bridges AC 800M to batch process controllers (Modbus-TCP) and safety instrumented systems (SIS) via DNP3.0.
• Legacy System Retrofitting: Modernizes older automation infrastructure in:
  • Manufacturing Facilities: Connects AC 800M to legacy Siemens S5 PLCs (via PROFIBUS DP) and Allen-Bradley SLC 500 systems (via Ethernet/IP).
  • Water Treatment Plants: Integrates with 20-year-old SCADA systems (Modbus-RTU) and new AC 800M-based pump controls.
• Remote I/O Networking: Extends AC 800M connectivity to distributed I/O in:
  • Mining Operations: Links surface AC 800M controllers to underground PROFIBUS DP I/O stations (sensors, valves).
  • Pipeline Networks: Connects central AC 800M to remote Modbus-TCP I/O for pressure/flow monitoring.
• Cross-Plant Data Sharing: Facilitates data exchange between AC 800M and enterprise systems in:
  • Pharmaceutical Facilities: Transmits batch data to MES (Manufacturing Execution Systems) via Ethernet/IP.
  • Food Processing Plants: Shares production metrics with ERP systems (via Modbus-TCP) for inventory tracking.

4. Precautions

• AC 800M Exclusivity: Use only with ABB AC 800M DCS racks. Installation in non-AC 800M systems (e.g., AC 500 PLCs, third-party DCS) will cause backplane communication failure and module damage.
• Protocol Configuration: Avoid conflicting protocol settings (e.g., same baud rate for two serial ports). Use Control Builder M to validate protocol assignments—misconfiguration causes data corruption or connection drops.
• Cable Compliance:
  • Ethernet: Use shielded Cat5e/Cat6 (1Gbps requires Cat5e+).
  • PROFIBUS: Use certified PROFIBUS DP cable (100Ω impedance); activate built-in terminator only at segment ends.
  • Serial: Use twisted-pair shielded cable for RS-485 (max 1200m at 9600bps).
• Grounding: Ground all port shields and the module’s ground terminal to AC 800M rack ground (≤1Ω). Poor grounding reduces isolation effectiveness and increases EMI susceptibility.
• Redundancy Setup: Configure Ethernet redundancy (MRP/PRP) and PROFIBUS redundant segments via Control Builder M. Test failover by disconnecting primary links—ensure switchover occurs within 50ms.
• Firmware Updates: Update firmware via Control Builder M (back up configurations first). Mismatched firmware between CI930F and AC 800M causes protocol incompatibilities.
• Maintenance: Inspect quarterly:
  • Verify LED status (no red faults; redundant ports show green).
  • Test serial/PROFIBUS connections with a protocol analyzer.
  • Clean ports with compressed air to remove dust (prevents intermittent faults)

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