ABB CI860 / CI860K01 / 3BSE032444R1 – Communications Input Module | AC 800M Series
Engineering Background
The CI860 is ABB’s dedicated PROFIBUS DP communications interface module designed for the AC 800M high-integrity distributed control system platform. It bridges field-level PROFIBUS DP networks with the AC 800M controller backplane, enabling deterministic, high-speed data exchange between the DCS and intelligent field devices, remote I/O stations, and third-party subsystems. Part number 3BSE032444R1 is the standard commercial variant; CI860K01 denotes the kit configuration inclusive of mounting hardware.
Product Positioning
Targeted at process automation engineers and system integrators operating in oil & gas, power generation, chemical, and pulp & paper industries, the CI860 is the preferred choice when PROFIBUS DP fieldbus connectivity must be embedded directly within the AC 800M controller chassis — eliminating the need for external gateways and reducing latency, wiring complexity, and single-point-of-failure risk.
Complete Technical Specifications
- Part Numbers: CI860 / CI860K01 / 3BSE032444R1
- Manufacturer: ABB Automation Products GmbH (formerly ABB Asea Brown Boveri)
- Platform: AC 800M DCS Controller Series
- Module Type: Communications Input Module – PROFIBUS DP Master
- Fieldbus Protocol: PROFIBUS DP (EN 50170 / IEC 61158)
- PROFIBUS Role: Class 1 DP Master (DPM1)
- Max. DP Slaves: Up to 125 slave devices per segment
- Baud Rate: 9.6 kbps – 12 Mbps (auto-negotiated)
- Connector: 9-pin D-Sub (DB9) female, RS-485
- Isolation: Galvanic isolation between fieldbus and backplane
- Backplane Interface: AC 800M S800 I/O bus
- Power Supply: Supplied via controller backplane (no external PSU required)
- Power Consumption: ≤ 3 W (typical)
- Operating Temperature: 0 °C to +55 °C
- Storage Temperature: −40 °C to +70 °C
- Relative Humidity: 5 % – 95 % RH (non-condensing)
- Dimensions (H × W × D): Conforms to AC 800M module form factor
- Weight: Approx. 200 g
- Certifications: CE, UL, cUL, ATEX (zone 2 when installed in certified enclosure)
- Firmware: Upgradeable via ABB Control Builder M
- Redundancy Support: Compatible with redundant controller configurations
- RoHS Compliance: Yes
Proven Application Environments
- Oil & Gas: Upstream wellhead RTU integration, downstream refinery DCS expansion via PROFIBUS DP remote I/O (e.g., ABB S800 I/O clusters)
- Power Generation: Turbine control systems requiring high-speed cyclic data exchange with intelligent electronic devices (IEDs)
- Chemical & Petrochemical: Reactor loop control with PROFIBUS-connected valve positioners (e.g., ABB TZIDC, Siemens SIPART PS2)
- Pulp & Paper: Distributed drive control via PROFIBUS DP to ABB ACS800 / ACS880 frequency converters
- Water & Wastewater: SCADA-integrated pump station control with remote I/O over PROFIBUS DP
- Pharmaceutical (FDA 21 CFR Part 11): Validated batch control architectures requiring deterministic fieldbus communication
Engineering Advantages
- Native Backplane Integration: Slots directly into the AC 800M controller rack — no external DP master hardware, no additional power rail, no gateway latency.
- Deterministic Cycle Times: PROFIBUS DP cyclic polling ensures sub-millisecond I/O update rates at 12 Mbps, critical for fast control loops.
- Galvanic Isolation: Protects the controller backplane from fieldbus ground loops and transient surges common in industrial environments.
- Redundancy-Ready: Supports hot-standby controller redundancy configurations, enabling bumpless transfer without fieldbus disruption.
- Broad Slave Compatibility: Certified interoperability with all GSD-file-compliant PROFIBUS DP slaves — vendor-agnostic integration.
- Firmware Upgradeable: Field-upgradeable via ABB Control Builder M, extending service life without hardware replacement.
- Compact Form Factor: Single-slot module preserves rack space in space-constrained control cabinets.
System Architecture & Signal Flow
The CI860 occupies a dedicated module slot in the AC 800M controller rack. On the fieldbus side, the DB9 connector interfaces to the PROFIBUS DP segment cable (shielded twisted pair, 150 Ω characteristic impedance). The module acts as DP Master Class 1, cyclically polling configured slave devices and exchanging process data (inputs/outputs) with the AC 800M CPU via the internal S800 I/O bus. Configuration and GSD file management are handled entirely within ABB Control Builder M — no separate PROFIBUS configuration tool is required. Acyclic DP-V1 services are supported for parameter access and diagnostics on intelligent field devices.
Typical signal flow: AC 800M CPU ↔ S800 Backplane Bus ↔ CI860 Module ↔ PROFIBUS DP Segment ↔ Remote I/O / Drives / Positioners / Analyzers
Sourcing & Quality Verification
- Origin: Sourced from authorized ABB distributors and verified industrial surplus channels.
- Inspection Protocol: Each unit undergoes visual inspection, label verification (part number, revision, date code), and functional power-on test prior to dispatch.
- Packaging: Anti-static bag + foam-lined carton; original ABB packaging retained where available.
- Traceability: Serial number and revision level documented per order for full audit trail.
- Warranty: 90-day operational warranty against manufacturing defects; extended warranty available on request.
- Counterfeit Prevention: All units verified against ABB’s published part number and revision matrix; suspect units are quarantined and not listed.
Procurement Process
- Step 1 – Inquiry: Submit your BOM line or RFQ via email to [email protected] or WhatsApp +0086 19859288691 with required quantity and delivery timeline.
- Step 2 – Quote: Receive a formal quotation within 1 business day including unit price, lead time, and shipping options (DHL / FedEx / sea freight).
- Step 3 – Order Confirmation: Issue PO or confirm via email; proforma invoice issued for payment processing.
- Step 4 – Payment: T/T bank transfer, PayPal, or trade assurance accepted.
- Step 5 – Dispatch: Units shipped within 2–5 business days of payment confirmation; tracking number provided same day.
- Step 6 – After-Sales: Technical support available post-delivery for installation and commissioning queries.
Technical FAQ
- Q: Is the CI860 compatible with AC 800M firmware versions prior to 5.0?
- A: The CI860 is supported from AC 800M firmware 4.0 onwards. For firmware versions below 5.0, verify GSD file compatibility in Control Builder M before deployment.
- Q: Can the CI860 operate as a PROFIBUS DP slave?
- A: No. The CI860 is exclusively a DP Master Class 1 device. For slave functionality, ABB offers separate communication modules.
- Q: What is the maximum cable length per PROFIBUS DP segment?
- A: At 12 Mbps, maximum segment length is 100 m. At 1.5 Mbps, up to 200 m. Repeaters can extend total network reach to 1,200 m (at lower baud rates).
- Q: Does the CI860 support PROFIBUS PA?
- A: Not directly. PROFIBUS PA requires a DP/PA coupler or link device between the CI860 DP segment and the PA segment.
- Q: Is a bus terminator required?
- A: Yes. Both ends of the PROFIBUS DP segment must be terminated with 220 Ω / 390 Ω resistor networks (typically integrated into PROFIBUS connectors with termination switches).
- Q: Can I use the CI860 in a redundant controller configuration?
- A: Yes. When paired with a redundant AC 800M CPU pair, the CI860 supports bumpless switchover. Each controller requires its own CI860 module.
- Q: What documentation is available?
- A: ABB publishes the CI860 User Manual (3BSE032444R1 series) and the AC 800M Hardware Manual. Konmask can provide copies upon request.
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