CI853K01 is a complete communication interface solution kit launched by ABB for the industrial automation field. Its core components include the CI853 communication module and the essential TP853 mounting baseplate. This kit belongs to the industry-leading ABB Ability™ System 800xA® hardware ecosystem and is specifically designed to extend the serial communication capabilities of the high-performance AC 800M controller. The CI853K01 provides two standard, fully-functional RS-232C channels, aiming to solve the challenge of reliable and efficient data integration between various intelligent devices, instruments, drives, or legacy control systems with serial interfaces and the modern 800xA platform on the industrial floor.
In the context of Industry 4.0 and smart manufacturing, despite the increasing prevalence of Ethernet and other network technologies, traditional serial communications like RS-232/485 remain irreplaceable in industrial settings due to their simplicity, reliability, low cost, and widespread presence in a vast installed base of equipment. The CI853K01 is tailor-made for such application scenarios. By supporting a diverse protocol stack including ABB proprietary protocols, open standard protocols, and user-defined protocols, it acts as a "bridge" connecting new and old equipment and integrating heterogeneous systems. Its plug-and-play kit form simplifies procurement, storage, and installation processes for users, ensuring they receive a complete hardware unit that is fully compatibility-tested and ready for immediate deployment.
This product adheres to ABB's consistent design philosophy of high reliability, high environmental adaptability, and easy maintainability for industrial equipment. It supports features such as Hot Swap and DIN rail mounting, and has obtained multiple international industry certifications, making it suitable for demanding fields such as process industries (e.g., chemical, oil & gas), discrete manufacturing, energy management, and maritime platforms.
2. Hardware Composition and Design Analysis
The CI853K01 kit consists of two precisely matched hardware components that together form a fully functional communication interface unit.
2.1 CI853 Communication Module (Core Functional Unit)
The CI853 module is the "brain" and communication processing core of the kit. Its design is compact, with dimensions of 59 mm (W) x 185 mm (H) x 127.5 mm (D), housed in a rugged industrial-grade enclosure.
Internal Architecture: The module integrates a high-performance microprocessor, Flash Memory (FPROM), Static RAM (SRAM), dual-port RAM, and two independent serial communication controllers. An efficient DC/DC power conversion circuit converts the 24V power obtained from the CEX bus to the 5V operating voltage required by internal chips.
Status Indication: The module's front panel features an intuitive array of multi-color LED indicators, serving as a crucial diagnostic window:
Run (Green): Steady on indicates normal module operation and fault-free communication with the controller.
Fault (Red): Illuminated indicates a hardware or severe communication error detected internally by the module.
Tx1 / Rx1 / Tx2 / Rx2 (Yellow): Correspond to data transmission and reception activity for the COM1 and COM2 ports, respectively. The flashing frequency visually reflects communication traffic.
2.2 TP853 Mounting Baseplate (Interface and Carrier Platform)
The TP853 baseplate is the physical carrier and electrical interface platform for the CI853 module, an indispensable part of the kit.
Mounting Interface: Provides standard DIN rail clips for secure mounting on standard rails inside control cabinets. The baseplate design includes a mechanical keying device (two-letter Alpha code) that physically prevents the incorrect installation of incompatible modules, greatly enhancing system reliability.
Communication Interface: The baseplate integrates two RJ-45 type 8-pin connectors, clearly labeled COM1 and COM2. This connector type offers a balance of connection convenience and reliability in industrial environments. All RS-232C signal lines (including data and modem control lines) are routed through these connectors.
Electrical Connection: The baseplate is responsible for reliably transmitting power and data signals from the CEX bus on its rear to the CI853 module. It also provides a convenient grounding terminal for the communication cable shield, which is essential for ensuring electromagnetic compatibility (EMC).
2.3 Kit Integration Advantages
Providing CI853 and TP853 as a kit offers significant benefits to users:
Compatibility Assurance: Ensures users receive a fully compatible module and baseplate combination that has undergone rigorous ABB testing, eliminating the risk of version mismatch from separate purchases.
Easy Installation: The box contains all necessary hardware, simplifying material preparation and installation steps for personnel.
Convenient Maintenance: As a unified spare part unit, the entire CI853K01 kit can be replaced directly during field maintenance, simplifying spare parts management and maintenance operations.
3. Core Features and Protocol Support
The core value of CI853K01 lies in its powerful software configurability and broad protocol support.
3.1 Multi-Protocol Support (Software-Defined)
The communication protocol is not fixed by hardware but is configured and licensed through System 800xA engineering software, providing great flexibility:
COMLI Protocol: ABB's proprietary, efficient inter-controller communication protocol. Supports Master/Slave modes, optimized for half-duplex asynchronous communication. Its unique advantage is supporting software-controlled dial-up modems and, when combined with fiber optic converters, extending communication distances to several kilometers, making it ideal for connecting remote sites or distributed I/O.
MODBUS RTU Protocol: The world's most widely used open serial protocol standard. CI853K01 operates in Master mode for MODBUS RTU, enabling easy connection to third-party sensors, instruments, variable frequency drives, etc., that support Modbus for data acquisition and control.
Siemens 3964R Protocol: Provides a standard solution for connecting Siemens S5, early S7 series PLCs, or other devices supporting this protocol, facilitating system integration in multi-vendor environments.
User-Defined Protocols: For devices with special or proprietary serial protocols, engineers can use the development toolkit provided by ABB to write dedicated communication drivers for the CI853, enabling interfacing with any serial device.
3.2 Configurable Communication Parameters
Communication parameters for each port can be independently and flexibly configured:
Baud Rate: Selectable from 75 bps to 19200 bps, with up to 12 standard step values available (e.g., 300, 1200, 9600, 19200) to meet the speed requirements of different devices.
Data Format: Data bits (7/8), stop bits (1/2), and parity (None, Odd, Even) can all be freely set.
Flow Control: Supports flow control via RTS/CTS hardware handshake signals, ensuring reliable high-volume data transmission with devices that have buffers (e.g., modems, certain computers).
3.3 Hot Swap Functionality
This is a key high-availability feature of CI853K01. When the system is running, if maintenance, upgrade, or replacement of the CI853 module is required, personnel can safely remove the faulty module and insert a new one without powering down or stopping the controller application. The system automatically recognizes the new hardware and re-establishes communication. This process minimizes impact on the control logic, greatly enhancing the overall operational continuity and maintainability of the plant.
4. System Integration and Expansion Capability
4.1 Seamless Integration with AC 800M Controllers
CI853K01 connects to the AC 800M controller (e.g., PM8xx series) via the CEX (Communication Extension) Bus. It draws 24V DC power and communication clock directly from the bus, requiring no additional power distribution, which simplifies system wiring. An AC 800M controller can expand multiple communication modules via its CEX bus, with CI853K01 being a key member for serial communication.
4.2 Communication Distance Extension Solutions
The standard direct cable connection distance is 15 meters. To meet longer-distance communication needs, ABB provides a complete solution:
Using the TC562 Short-Distance Modem: This solution can significantly increase the range. At 19200 baud, a reliable distance of 1000 meters can be achieved; at 1200 baud, the distance can be extended to an impressive 12000 meters. The TC562 requires separate power supply and mounting on a DIN rail.
4.3 System Scalability
Up to 12 expansion units (including CI853, network modules, I/O modules, etc.) can be connected on a single CEX bus. This means a single AC 800M controller can be flexibly configured with dozens of serial communication ports, sufficient to meet the most complex communication interface requirements.
5. Environmental Adaptability and Reliability Certifications
The design of CI853K01 fully considers harsh industrial environments:
Operating Temperature Range: 0°C to +55°C, ensuring stable operation in most industrial indoor environments.
Wide Storage Temperature Range: -40°C to +70°C, facilitating global transportation and storage.
Corrosion Protection: Compliant with ISA 71.04 G3 level, capable of withstanding moderately corrosive gaseous environments, suitable for industries like chemicals and paper.
Protection Rating: IP20, preventing finger contact with live parts and providing a degree of dust protection, suitable for installation inside control cabinets.
Authoritative Industry Certifications:
CE Marking: Complies with EU health, safety, and environmental standards.
Marine Certifications: Simultaneously certified by ABS (American Bureau of Shipping), BV (Bureau Veritas), DNV GL, and LR (Lloyd's Register), meeting the stringent requirements for shipboard and offshore platform applications.
Environmental Compliance: Fully complies with EU RoHS (2011/65/EU) and WEEE (2012/19/EU) directives, reflecting ABB's commitment to environmental and social responsibility.
6. Application Areas and Value
CI853K01 is widely used in the following scenarios, creating significant value for customers:
Process Industries: Connecting field-mounted smart transmitters, analyzers, flow meters, valve positioners (supporting protocol conversion like HART).
Manufacturing Execution System (MES) Integration: Serving as a data gateway between shop-floor devices (e.g., older CNC machines, robot controllers) and upper-level MES/ERP systems.
Building Automation & Energy Management: Connecting serial interfaces of equipment like chillers, boilers, and power monitoring meters.
Maritime & Shipbuilding: Connecting subsystem devices with serial interfaces in ship navigation, power management, and cabin control systems.
System Retrofit & Upgrade: Preserving and utilizing existing serial communication networks when migrating or integrating legacy DCS or PLC systems into the ABB System 800xA platform.
Its value is reflected in: Reducing integration costs (utilizing existing serial networks), Improving data availability (integrating data from isolated devices into a unified platform), Enhancing system reliability (Hot Swap and industrial-grade design), and Ensuring return on investment (extending the service life of existing equipment).
