ABB CI810B 3BSE020520R1 Fieldbus Communication Interface Module

The CI810B AF 100 Fieldbus Communication Interface Module is a high-performance, high-reliability industrial communication interface device launched by ABB, specifically designed for the S800 I/O system. It facilitates efficient data exchange and protocol conversion between the Advant Fieldbus 100 (AF 100) and the ModuleBus. As a critical component in industrial automation control systems, this module is widely used in distributed I/O stations across sectors such as power generation, process industries, and manufacturing. It is responsible for connecting the upper-level control network with field I/O devices, enabling signal acquisition, processing, and transmission.

The CI810B is a significant upgrade within the CI810 series, offering notable improvements in hardware design, software functionality, and system compatibility. The module supports dual AF 100 interfaces, enabling communication media redundancy to enhance system availability. Its built-in high-performance processor and large-capacity memory can handle complex communication tasks and data pre-processing. It also supports online software upgrades and module hot-swapping, greatly facilitating system maintenance and expansion.

This product is typically used in conjunction with accessories such as the TB807 ModuleBus Terminator, power supply connector, and terminal blocks. It comes pre-loaded with the basic system software (Version 1.5), making it ready for immediate integration into existing or new control systems like Advant OCS, 800xA, or Compact Product Suite.

2. Key Product Features

1. Dual AF 100 Interface Redundancy Design: The module is equipped with two independent AF 100 twisted-pair modem interfaces, supporting redundant cable configuration to ensure system operation continues even if one line fails.

2. High-Performance Processing Core: Utilizes a Motorola MC68340 series microprocessor running at 16 MHz, providing powerful real-time data processing and protocol handling capabilities.

3. Large-Capacity Memory Support: Features 512 KB Flash PROM and 512 KB battery-backed RAM for storing application programs, configuration parameters, and runtime data, supporting local execution of complex control logic.

4. Modularity and Hot-Swappability: Allows module replacement without system downtime. Combined with a pluggable terminal header design, it facilitates easy installation, debugging, and maintenance.

5. Comprehensive Diagnostics and Status Indication: The front panel is equipped with multiple LED indicators that display real-time module status, power status, communication traffic, and fault information for quick on-site diagnosis.

6. Flexible Power Supply Configuration: Supports single or redundant 24V DC power input and can monitor the status of each supply to ensure power reliability.

7. Optical ModuleBus Expansion Support: Compatible with the optional TB810/TB811 Optical ModuleBus Port, enabling I/O station distance extension via fiber optic cables and enhancing noise immunity.

8. Wide Temperature and Voltage Range Design: Power input range of 19.2–30V DC, suitable for complex power environments in industrial settings.

   
   

3. System Architecture and Working Principle

The CI810B acts as a communication hub within an S800 I/O station. Its system architecture can be divided into three layers:

1. Upper Network Interface Layer: Connects to an Advant Controller (e.g., AC 410) or other master station via two AF 100 twisted-pair interfaces. It acts as a "slave station" on the AF 100 bus, receiving control commands and uploading I/O data.

2. Core Processing Layer: Consists of the MC68340 CPU, memory, and dedicated communication chips. It handles protocol parsing, data mapping, fault diagnosis, module configuration, and real-time scheduling.

3. Lower I/O Interface Layer: Acts as the master on the ModuleBus, managing up to 12 local I/O modules (via Electrical ModuleBus) or up to 24 modules via optical expansion. It performs read/write operations, status collection, and channel configuration.

The module supports cyclic data exchange and event-triggered communication. The cycle time is configurable from 1 to 4096 ms, meeting the needs of applications with different real-time requirements. In a redundant configuration, two CI810B modules can work together via a TB815 Interconnection Unit to achieve full redundancy for both AF 100 channels and the ModuleBus.

4. Product Application Areas

The CI810B is suitable for various industrial scenarios requiring high reliability, real-time communication, and distributed I/O control, including:

• Power Automation: Plant DCS systems, substation monitoring, distribution automation.

• Process Industries: Control and monitoring in oil & gas, pharmaceuticals, water treatment, food & beverage.

• Manufacturing: Automotive production lines, steel rolling, packaging machinery, semiconductor manufacturing equipment.

• Infrastructure: Building automation, traffic control, energy management.

• Retrofit & Upgrade Projects: Replacing older CI810/CI810A modules to enhance system communication performance and maintainability.

  
  

5. Installation and Configuration Guide

1. Mechanical Installation

• The module is designed for DIN rail mounting and can be installed horizontally or vertically.

• Ensure the installation environment meets the IP20 protection requirement, avoiding dust, moisture, and corrosive gases.

2. Electrical Connections

• Power Supply Wiring: Connect the 24V DC power supply to terminals X1A (L+) and X1B (L-). Parallel connection for redundant supplies is supported.

• AF 100 Wiring: Use shielded twisted-pair cable (Belden 9182 or equivalent recommended) to connect to terminals X2 (Channel 1) and X3 (Channel 2). Ensure the shield is grounded at one end only.

• ModuleBus Wiring: Connect local I/O modules via the backplane bus. The TB807 terminator must be installed after the last MTU.

• Optical Expansion: For remote I/O clusters, connect fiber optic cables to the Optical ModuleBus Port via TB810/TB811.

3. Address Setting

• Set the station address (01–79) using the two rotary switches on the front of the module. Both modules in a redundant CI820 pair must be set to the same address.

4. Software Configuration

• Configure communication parameters, data mapping, and diagnostic functions using system engineering tools like Advant Engineer or 800xA.

• Supports basic software upgrades via the service port (RS-232) connected to a PC. Refer to the Software Upgrade Guide for the procedure.

5. Status Monitoring and Diagnostics

• Monitor module status in real-time via front panel LEDs:

• F (Red): Fault indication.

• R (Green): Normal operation.

• P (Green): Internal power OK.

• T1/T2 (Yellow): AF 100 channel communication activity.

• Tx/Rx (Yellow): Optical ModuleBus transmission/reception activity.

  
  

6. Maintenance and Troubleshooting

1. Routine Maintenance

• Periodically check power supply voltage, connection tightness, and LED indications.

• Ensure adequate ventilation around the module to prevent overheating.

2. Common Fault Handling

• F-LED Constantly Lit: Check power supply, address settings, bus connections, or perform a module restart.

• Communication Interruption: Check AF 100 cables, termination resistors, grounding, and master station configuration.

• Module Not Recognized: Verify the ModuleBus terminator is correctly installed and check I/O module power supply.

3. Software Upgrade and Reset

• Application memory can be cleared by setting the address switches to 99 and cycling the power.

• Software upgrade requires a TK527 cable to connect a PC to the service port. Follow the steps to load the new basic software version.