ABB CI801

Description

Detailed Parameter Table

ABB CI801

Product introduction

The CI801 is a reliable communication interface module from ABB, specifically designed to enable seamless data exchange between the AC800M controller and Modbus-based field devices in industrial automation systems. As a key component in ABB’s S800 I/O ecosystem, it serves as a critical bridge for transmitting real-time process data and control signals, ensuring efficient operation of industrial processes that rely on Modbus protocol.

This module is fully compatible with ABB’s AC800M controller and S800 I/O system, working harmoniously with terminal bases like the TB820V2. The CI801 supports Modbus RTU and ASCII protocols, facilitating both cyclic data exchange (for real-time control) and acyclic data transfer (for configuration and diagnostics), making it highly versatile for applications involving Modbus-enabled sensors, actuators, and instruments.

Constructed to withstand harsh industrial environments, the CI801 operates reliably across a wide temperature range and resists electromagnetic interference. Its compact design and easy installation make it an essential component for integrating Modbus devices into ABB’s automation architecture, ensuring smooth and transparent communication throughout the system. Compared to the CI810B 3BSE020520R which focuses on Profibus DP-V1, the CI801 is specialized for Modbus networks, catering to different communication protocol needs in industrial settings.

Core advantages and technical highlights

Flexible Modbus communication

The CI801 supports Modbus RTU and ASCII protocols with configurable data transfer rates from 300 bps to 115.2 kbps, allowing it to adapt to various Modbus network requirements. This flexibility makes it suitable for both short-distance, high-speed communication (such as in a packaging line) and long-distance, lower-speed transmission (like in a water treatment plant). For example, in a municipal wastewater treatment facility, it can transmit data from Modbus-enabled level sensors to the AC800M controller at 9600 bps, ensuring accurate monitoring of tank levels.

Seamless integration with ABB ecosystem

Designed specifically for ABB’s AC800M controller and S800 I/O system, the CI801 eliminates compatibility issues often encountered with third-party modules. It works seamlessly with the TB820V2 terminal base, providing a secure and organized wiring interface for power and signal lines. When paired with I/O modules such as the AI810 3BSE008516R0001 analog input module, it enables the AC800M controller to receive and process data from a wide range of Modbus-based devices, creating a unified automation network. Unlike the CI810B 3BSE020520R which integrates with Profibus devices, the CI801 is tailored for Modbus devices, expanding ABB’s communication coverage.

Simplified diagnostics and troubleshooting

Equipped with intuitive LED indicators, the CI801 provides clear visual feedback on power status, communication activity, and error conditions. A steady green power LED and a flashing green communication LED indicate normal operation, while a red fault LED alerts technicians to issues such as communication failures or power supply problems. This simplifies troubleshooting, allowing quick identification of issues like loose connections or incorrect baud rate settings. The module also supports Modbus diagnostic functions accessible via the AC800M controller, enabling retrieval of detailed error logs and minimizing downtime in critical processes.

ABB CI801

Typical application scenarios

In a food processing plant, the CI801 acts as the communication link between the AC800M controller and a network of Modbus-enabled devices, including temperature controllers, flow meters, and weighing scales. The module is connected to the TB820V2 terminal base, which organizes wiring for power and auxiliary signals. It transmits real-time data from these devices to the controller at 19200 bps, enabling the controller to adjust processing parameters such as heating times and conveyor speeds to ensure product quality.

When a Modbus-enabled pH sensor in a mixing tank detects an out-of-range value, the CI801 quickly transmits this data to the AC800M controller. The controller then sends a control signal back through the CI801 to a Modbus-based valve, adjusting the flow of additives to correct the pH level. The module’s diagnostic LEDs provide immediate visibility into communication status, allowing technicians to quickly resolve any issues and maintain uninterrupted production.

In a manufacturing facility with legacy Modbus equipment, the CI801 facilitates the integration of these devices into ABB’s modern automation system. It connects to Modbus-based motor drives and pressure sensors, enabling the AC800M controller to monitor and control these legacy devices alongside newer equipment, avoiding the need for costly replacements and ensuring a smooth transition to advanced automation.

Related model recommendations

• CI800: A predecessor to the CI801with similar Modbus functionality but slightly lower data transfer rates, suitable for less demanding applications.
• CI810B 3BSE020520R: A Profibus DP-V1 communication module that, when used alongside the CI801, enables the AC800M controller to communicate with both Modbus and Profibus devices, expanding system versatility.
• TB820V2: A terminal base that provides secure wiring connections for the CI801, ensuring organized installation and reliable signal transmission.
• AI810 3BSE008516R0001: An analog input module that, when paired with the CI801, allows the AC800M controller to process data from additional analog sensors connected via the Modbus network.
• 3BHE009017R0102: A power supply module that delivers stable 24 V DC power to the CI801, ensuring consistent and reliable operation.
• TU840: A terminal unit that works with the CI801in large-scale systems, providing additional wiring points for a greater number of Modbus devices.
• TC514V2 3BSE013281R1: A temperature controller module that, when integrated with the CI801, enables temperature data to be transmitted to the AC800M controller via the Modbus network.

Installation, commissioning and maintenance instructions

Installation preparation

Before installing the CI801, ensure the control cabinet is clean, dry, and free from dust or conductive debris. The ambient temperature should be within -25°C to +70°C, with relative humidity not exceeding 95% (non-condensing). Required tools include a small screwdriver, wire strippers, a Modbus cable tester, and a torque wrench.

Mount the CI801 on a 35 mm DIN rail, ensuring it is securely fastened and positioned for easy access. Leave at least 15 mm of space around the module for ventilation. Connect the 24 V DC power supply (from a 3BHE009017R0102 module) to the removable terminal block, ensuring correct polarity. Use shielded twisted-pair cables for the RS485 port, with shields grounded at both ends to minimize electromagnetic interference. Double-check all wiring connections before powering on the system.

Maintenance suggestions

For daily maintenance of the CI801, visually inspect the module for physical damage, loose connectors, or discolored components (indicating overheating). Check LED indicators regularly: a steady green power LED and flashing green communication LED indicate normal operation, while a red fault LED signals an issue (refer to the manual for fault codes).

Inspect Modbus cables and connectors quarterly for damage, corrosion, or loose connections, which can cause communication failures. Clean the module with compressed air (low pressure) to remove dust. If a fault persists, reset the module by powering it off and on. If issues continue, replace with an ABB-approved spare, ensuring the replacement is configured with the same parameters (baud rate, parity, etc.) as the original. Always power down the system before replacing the module to prevent data corruption.

Service and guarantee commitment

The CI801 is backed by ABB’s 3-year warranty, covering defects in materials and workmanship under normal operating conditions. During the warranty period, ABB will repair or replace faulty modules free of charge, minimizing operational disruptions.

ABB’s technical support team provides 24/7 assistance for installation, configuration, and troubleshooting of the CI801. We offer comprehensive documentation, including wiring diagrams and protocol specifications, to help integrate the module with the AC800M controller, TB820V2 terminal base, and other components.

Extended service contracts are available, offering priority support, on-site maintenance, and software updates to ensure compatibility with future system upgrades. ABB’s global service network ensures fast delivery of replacement modules, reducing downtime in critical applications. Trust the CI801 to deliver reliable Modbus communication, backed by ABB’s expertise in industrial automation.