CI865K01 3BSE040795R1 | AC 800M Communication Interface Module

Description

1. Communication Protocols and Compatibility

PROFINET Standard Support

• Compliant with the PROFINET IO V2.3 standard, supporting Real-Time (RT) and Isochronous Real-Time (IRT) communication, suitable for industrial automation scenarios with extremely high time synchronization requirements (e.g., motion control, high-speed production lines).
• Can function as a PROFINET IO Controller or Intelligent Device (I-Device) for flexible integration into PROFINET networks.

Device Compatibility

• Supports seamless communication with PROFINET slave devices from major manufacturers (e.g., sensors, actuators, drives, third-party controllers).
• Compatible with other ABB PROFINET modules (e.g., DI/DO, AI/AO modules) and third-party PROFINET devices.

2. Performance and Functional Features

High Real-Time Performance and Reliability

• In IRT mode, the communication cycle can be as low as 1 ms, with synchronization accuracy up to 1 μs, meeting the needs of high-speed motion control and precise synchronization.
• Supports redundant network configuration (dual-port switch) to ensure seamless switching during network outages and enhance system reliability.

Data Processing Capability

• Supports a maximum of 1,440 bytes of input/1,440 bytes of output process data, enabling connection to a large number of distributed I/O devices.
• Supports asynchronous communication (S7 communication, TCP/IP, UDP) for transmitting parameters, diagnostic data, or communicating with supervisory computers (e.g., SCADA, MES).

Time Synchronization and Diagnostics

• Supports IEEE 1588 v2 precise clock synchronization to ensure time consistency across the network.
• Built-in comprehensive diagnostic functions, enabling real-time monitoring of network status and module faults (e.g., link interruptions, slave device failures) via LED indicators and ABB Control Builder software.

3. Hardware Design and Installation

Compact Modular Design

• Can be installed on ABB AC 800M controller racks (e.g., PM861/PM866 CPU modules) and communicates with the controller via the backplane bus.
• Physical interfaces: 2 PROFINET RJ45 ports (supporting auto-cross connection), enabling direct connection or network expansion via switches.

Environmental Adaptability

• Operating temperature: -20°C ~ +60°C, suitable for harsh industrial environments.
• Protection level: IP20 (rack-mounted), meeting installation requirements in standard control cabinets.

4. Software Configuration and Integration

Configuration Tools

• Uses ABB Control Builder M software for network configuration, parameter setting, and diagnostics, supporting import of GSDML files (PROFINET device description files) for integrating third-party slaves.
• Can be used with ABB’s Automation Builder or third-party engineering tools (e.g., TIA Portal) to achieve cross-platform system integration.

Programming and Communication Functions

• In ABB AC 800M controllers, communication function blocks (FBs) are called via IEC 61131-3 programming languages (e.g., Ladder Diagram LD, Structured Text ST) to implement data reading/writing and control logic.
• Supports PROFINET Device Replacement (DR) and Firmware Over-The-Air (FOTA) to reduce downtime.

5. Application Scenarios

• Manufacturing: Automotive production lines, electronics assembly, packaging machinery (high-speed synchronization control).
• Process Automation: Distributed control systems (DCS) in chemical, pharmaceutical, and food/beverage industries.
• Motion Control: Real-time communication with robots and servo drive systems (e.g., integration with ABB IRC5 robot controllers).
• Energy and Infrastructure: Monitoring and data acquisition (SCADA) in smart grids and wastewater treatment plants.

Technical Parameters

• Communication Function: Satt ControlNet communication interface for AC 800M systems, bridging different bus standards used on AC 800M and Satt ControlNet.
• I/O Scanning Capability: Can handle I/O scanning for up to 31 distributed I/O systems.
• Electrical Parameters: Typical 24V power consumption of 120mA.
• Mechanical Parameters:
• Dimensions: 185mm (H) × 59mm (W) × 127.5mm (D) [7.3in. × 2.3in. × 5.0in.].
• Weight: Approximately 700g (1.5lbs) including the base.
• Hot Swap Function: Supports online replacement (hot swapping) with no pre-installation configuration required.
• CEX Bus: Maximum 4 units on the CEX bus.
• Connector Type: BNC.
• Environmental Parameters:
• Operating temperature: 55°C.
• Protection level: IP20 per EN 60529 and IEC 529 standards.

How to Install and Configure the ABB CI865K01 3BSE040795R1 Module?

1. Module Overview

• Model: CI865K01 (3BSE040795R1)
• Type: Communication interface module (typically for PROFIBUS DP or fieldbus communication).
• Application: Connects PLCs with field devices (e.g., sensors, actuators) to enable data exchange.

2. Installation Steps

Hardware Installation

• Tools Required: Screwdriver, anti-static wristband, module mounting rail (e.g., DIN rail).
• Procedure:
• Power Interface: Connect a DC power supply matching the module’s voltage requirements (e.g., 24V DC, note positive/negative polarity).
• Communication Interface: Connect the master station (e.g., PLC) and slave devices via PROFIBUS DP cables, ensuring proper termination resistor setup (typically enabled on the first and last modules in the bus).
• Grounding: Reliably ground the module’s grounding terminal to reduce electromagnetic interference.
1. Power Off: Ensure the control system is powered off to avoid electric shock or module damage.
2. Install Rail: Secure the DIN rail in a suitable position inside the control cabinet.
3. Fix Module: Clip the CI865K01 module onto the rail and secure it with screws (ensure the module is aligned with the slot).
4. Cable Connections:

System Integration

• Installation Location: Typically inserted into the designated slot of the controller rack (e.g., PM866 controller rack for ABB AC 800M) to ensure good contact with the backplane bus.
• Notes:
• The module’s installation direction must match the rack slot markings to avoid pin damage from forced insertion.
• If the module supports hot swapping, it can be replaced while the system is running; otherwise, power off before replacement.

3. Parameter Configuration

Software Tools Preparation

• Required Software:
• ABB Control Builder M (for AC 800M system configuration).
• PROFIBUS configuration tools (e.g., Siemens SIMATIC Manager or ABB-specific tools).
• Driver Installation: Ensure the software has loaded the GSD file for the CI865K01 module (download from the ABB official website).

Configuration Steps (Taking AC 800M as an Example)

1. Create Project: Open Control Builder M, create a new project, and add the controller (e.g., PM866).
2. Insert Module: Drag and drop the CI865K01 module into the corresponding slot in the rack configuration interface; the software will automatically recognize the module model.
3. Set Communication Parameters:
• Bus Type: Select PROFIBUS DP (based on the module’s supported protocol).
• Station Address: Set a unique address for the module on the bus (typically 0–126, consistent with the hardware DIP switch).
• Baud Rate: Match the bus speed (e.g., 9.6 kbps, 12 Mbps) with the slave devices.
• Profile: Select the module-supported profile (e.g., DP-V0, DP-V1).
4. Add Slave Devices: Scan and add slave devices (e.g., inverters, I/O modules) in the PROFIBUS network, and assign input/output addresses.
5. Download Configuration: Download the project configuration to the controller; the module status indicators (e.g., RUN, COM) should show normal status (green steady or blinking).

4. Status Inspection and Fault Troubleshooting

Indicator Lights

Common Issues and Solutions

• Communication Failure:
• Check bus cable connections and ensure termination resistors are enabled.
• Verify that the module and slave devices have matching addresses, baud rates, and protocols.
• No Power to Module:
• Measure power voltage and check fuses or power switches.
• Configuration Download Failure:
• Ensure software version is compatible with module firmware; try updating the module firmware via Control Builder M.