ABB CI853-1 communication interface module

ABB CI853-1 communication interface module

Product core positioning

The ABB CI853-1 communication interface module is a multi protocol communication conversion and system interconnection unit in the AC 800M series PLC. Its core function is to solve the interconnection problems of different protocol devices in industrial automation systems, and to build a communication bridge between the main processor (such as PM861K01, PM825) and third-party devices (such as DCS, frequency converters, instruments). Compared to conventional communication modules, it has multi protocol parallel processing, high bandwidth data transmission, and redundant communication capabilities, and can simultaneously support mainstream industrial Ethernet protocols such as PROFINET, EtherNet/IP, Modbus TCP, etc., breaking down communication barriers between devices from different manufacturers. Widely adaptable to scenarios such as petrochemical plant integration, cross platform scheduling of power systems, and collaboration of multiple metallurgical equipment, it is a key component for achieving seamless integration and data sharing between AC 800M systems and external systems.

Key technical parameters

（1） Communication Protocol and Rate Parameters

Support agreement

Industrial Ethernet protocol: PROFINET IRT (isochronous real-time) EtherNet/IP（CIP）、Modbus TCP； Serial protocol: Modbus RTU (supported through expansion modules)

Communication speed

Ethernet port: 10/100/1000 Mbps adaptive, PROFINET IRT real-time cycle ≤ 1 ms

Connection ability

Supports up to 256 TCP/IP connections, PROFINET IRT can connect up to 64 slave devices

Data transmission efficiency

The maximum transmission length of a single frame is 1500 bytes, and the data throughput per second is ≥ 100 Mbps

Time synchronization

Supports IEEE 1588 PTP v2 (accuracy ± 1 μ s) and PROFINET IRT synchronization (accuracy ± 100 ns)

（2） Hardware and power supply parameters

Power supply specifications

Input voltage 24 VDC (allowable fluctuation range ± 10%), power consumption ≤ 5 W, compatible with AC 800M system power supply

Size specifications

Width 40mm x height 100mm x depth 165mm, consistent with PM861K01 and PM825 dimensions, compatible with standard 35mm DIN rail installation

Environmental adaptability

Working temperature -25 ℃ to+70 ℃, storage temperature -40 ℃ to+85 ℃; Relative humidity ranging from 5% to 95% (no condensation); Vibration resistance level IEC 60068-2-6 (10-500 Hz, 10 g acceleration), impact resistance level IEC 60068-2-27 (15 g, 11 ms)

Protection level

Module body IP20, wiring terminal IP40, dust-proof and splash proof design

Isolation performance

250 VAC electrical isolation between Ethernet signal and power supply, anti common mode interference voltage ≥ 500 V

（3） Function and compatibility parameters

Redundant functions

Supports Ethernet redundancy (MRP, HSR) and power redundancy, with redundancy switching time ≤ 10 ms

Diagnostic function

Equipped with protocol fault diagnosis (such as connection interruption, data loss), module hardware fault diagnosis (such as port damage, power supply abnormality), and diagnostic information uploaded through the AC 800M system bus

Protocol conversion

Support bidirectional data conversion between different protocols (such as PROFINET and EtherNet/IP data interoperability)

Software compatibility

Supports Control Builder M V6.0 and above versions, and can configure protocol parameters and monitor communication status through software configuration

Expansion interface

2 Gigabit Ethernet RJ45 interfaces, 1 expansion serial interface (can connect to CI854 serial expansion module)

Core performance advantages

Multi protocol parallel processing and flexible adaptation: Supports three mainstream industrial Ethernet protocols: PROFINET IRT, EtherNet/IP, and Modbus TCP, allowing for seamless integration with devices from different manufacturers (such as Siemens PROFINET inverters, Rockwell EtherNet/IP PLCs, and Schneider Modbus TCP instruments) without the need to replace modules; The protocol conversion function can achieve cross protocol data interoperability (such as converting the speed data of PROFINET frequency converters into EtherNet/IP signals and uploading them to PM861K01), avoiding the need for additional protocol gateways and reducing system integration costs.

High real-time performance and precise synchronization: PROFINET IRT real-time cycle ≤ 1 ms, meeting the high-precision control requirements of industrial sites (such as multi motor synchronization of metallurgical rolling mills and robot motion control); Supports dual time synchronization of IEEE 1588 PTP v2 and PROFINET IRT, with accuracies of ± 1 μ s and ± 100 ns respectively, enabling microsecond level collaboration among multiple devices in distributed systems (such as synchronous control of temperature and feed flow in petrochemical reactors).

Redundant design and high reliability operation: Ethernet redundancy (MRP, HSR) and power redundancy are double guaranteed. When the main communication link or power supply fails, the backup link seamlessly switches within 10 ms to ensure uninterrupted transmission of critical data (such as power system dispatch data and chemical emergency stop signals); Electrical isolation and anti-interference design resist strong electromagnetic environments in industrial sites, with a communication error rate of less than 10 ⁻⁹, ensuring long-term stable operation.

Large capacity connectivity and efficient data exchange: With 256 TCP/IP connections and 64 PROFINET IRT slave access capabilities, it can adapt to the concurrent communication needs of multiple devices in large systems (such as real-time data exchange between dozens of robots and PLCs in automotive welding workshops); 1000 Mbps Ethernet port and 100 Mbps throughput, supporting industrial IoT big data transmission (real-time uploading of operating parameters of hundreds of devices to MES system).

Convenient diagnosis and operation optimization: Control Builder M software can monitor the communication status of each protocol in real time (such as connection count, data transmission rate, packet loss rate). When a protocol failure or hardware abnormality occurs, an alarm is immediately triggered and the fault location and cause are uploaded (such as "EtherNet/IP Port 2 connection interruption"), allowing operation and maintenance personnel to quickly locate the problem; Support online modification of protocol parameters without the need for power outages or restarts, reducing system downtime.

Typical application scenarios

Petrochemical plant system integration:

In a multi million ton refinery, the PM861K01 main CPU is interconnected with different systems through the CI853-1 communication interface module: the catalytic cracking unit controlled by Siemens S7-1500 PLC is connected through PROFINET IRT, the atmospheric and vacuum distillation unit controlled by Rockwell ControlLogix PLC is connected through EtherNet/IP, and the tank level data collected by Schneider RTU is connected through Modbus TCP; CI853-1 converts data from different protocols into a unified format and uploads it to PM861K01, achieving full process data sharing of "catalysis atmospheric and vacuum distillation tank area", while ensuring uninterrupted transmission of critical production data through redundant Ethernet.

Equipment collaboration in automotive manufacturing workshops:

In the automotive welding workshop, the PM825 PLC is connected to 20 KUKA welding robots (PROFINET slave stations) through the PROFINET IRT interface of the CI853-1 module, and real-time welding parameters (current, voltage, speed) are issued with a communication cycle of ≤ 1 ms to ensure synchronous welding of multiple robots (accuracy ± 0.1 mm); At the same time, connect the conveyor belt controlled by Rockwell inverter through EtherNet/IP interface to achieve "robot welding conveyor belt transfer" collaboration; The diagnostic function of CI853-1 can monitor the real-time communication status of robots. If a robot goes offline, it will immediately trigger an alarm and switch to a backup robot to avoid production line downtime.

Cross platform scheduling of power systems:

In the regional substation, PM861K01 is connected to the SCADA system of Nanwang Technology through the Modbus TCP interface of CI853-1, and uploads parameters such as transformer temperature (TC820-1 module data) and line current; Connect ABB REF615 relay protection device through EtherNet/IP interface to receive protection action signals; CI853-1 supports IEEE 1588 PTP v2 time synchronization, ensuring that the time deviation between SCADA systems and relay protection devices is ≤ 1 μ s, meeting the high-precision requirements of power grid dispatch for data timestamps; Redundant Ethernet design avoids power grid monitoring failures caused by communication interruptions.

Interconnection of food processing production line equipment:

In the food and beverage filling production line, the PM820-1 PLC is connected to multiple Schneider servo motors (controlling filling valves) through the Modbus TCP interface of CI853-1, and connected to Siemens visual inspection equipment (detecting filling liquid level) through the PROFINET IRT interface; CI853-1 converts visual inspection data (qualified/unqualified signals) into Modbus TCP signals, which are fed back to the servo motor control system to achieve closed-loop control of "filling detection removal"; The wide temperature adaptability of the module can operate stably in humid environments (relative humidity of 90%) in food workshops without the need for additional protective measures.