Product Overview
The ABB CI862 Industrial Automation Module serves as the communication interface between TRIO/Genius I/O blocks and the AC 800M controller. It integrates TRIO I/O as native AC 800M I/O, enabling seamless remote I/O management. The ABB CI862 connects directly to one TRIO LAN and includes a port for the Hand Held Monitor, simplifying on-site diagnostics.
With support for up to 30 TRIO blocks per LAN and a maximum system capacity of 1,000 I/O points, the CI862 is built for medium-to-large distributed control systems. Its ability to be configured redundantly enhances system reliability, making it a dependable choice for critical processes.
Key Features & Benefits
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High Capacity: The AC 800M controller supports up to four CI862 CEX modules, allowing expansion to 1,000 TRIO/Genius I/O points.
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Redundancy Ready: TRIO supports CEX module redundancy, providing failover protection for uninterrupted operations.
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Efficient I/O Management: The CI862 handles I/O configuration and scanning of up to 30 TRIO blocks, reducing controller workload.
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Hot Swap Support: The module supports hot swapping, minimizing downtime during maintenance or replacement.
Technical Specifications
| Parameter |
Value |
| Article Number |
3BUA000037R1 |
| Communication Protocol |
ABB's TRIO/Genius I/O |
| Life Cycle Status |
Classic |
| Master or Slave |
Master |
| Module Redundancy |
Yes |
| Hot Swap |
Yes |
| Max Units on CEX Bus |
4 |
| Connector Types |
Phoenix (4-pin), DB9 male, DB9 female |
| 24 V Consumption (typ.) |
190 mA |
| Operating Temperature |
+5 to +55 °C (+41 to +131 °F) |
| Storage Temperature |
-40 to +70 °C (-40 to +158 °F) |
| Relative Humidity |
5 to 95 %, non-condensing |
| Protection Class |
IP20 per EN60529, IEC 529 |
| CE Marking |
Yes |
| WEEE Compliance |
DIRECTIVE/2012/19/EU |
| Width |
59 mm (2.3 in.) |
| Height |
185 mm (7.3 in.) |
| Depth |
127.5 mm (5.0 in.) |
| Weight (including base) |
700 g (1.5 lbs) |
Industry Applications
The ABB CI862 Industrial Automation Module excels in process industries where reliable remote I/O is essential. In a chemical plant, for example, the module integrates field I/O from distributed TRIO blocks into the AC 800M controller, enabling centralized monitoring and control. Its redundancy capability ensures that a single module failure does not halt production, a critical advantage for continuous processes.
In a water treatment facility, the ABB CI862 interfaces with TRIO I/O to manage pumps, valves, and sensors across a wide area. The module's ability to handle up to 30 blocks per LAN reduces cabling and simplifies system architecture, lowering installation costs. The hot-swap feature allows maintenance without shutting down the entire plant, improving operational uptime.
Installation & Setup Guidance
Mount the ABB CI862 on a DIN rail in a suitable enclosure, ensuring adequate ventilation to maintain operating temperatures within +5 to +55 °C. Connect the TRIO LAN using the Phoenix (4-pin) connector for power and the DB9 connectors for communication. Use the Hand Held Monitor port for initial configuration and diagnostics.
Configure the CI862 as a master on the CEX bus. Set the module address and verify that the total number of connected TRIO blocks does not exceed 30 per LAN. For redundant operation, install two CI862 modules and configure them as a redundant pair. Follow the AC 800M controller's programming environment to map I/O points.
Maintenance & Reliability
Regularly inspect the CI862 for dust accumulation, especially on connectors and ventilation areas. Check all cable connections for tightness to prevent intermittent communication faults. Given the module's IP20 protection, ensure the enclosure maintains the specified environmental conditions (humidity 5–95% non-condensing).
Because the CI862 supports hot swapping, you can replace a faulty module without powering down the system, reducing downtime. Periodically monitor the module's 24 V consumption (typical 190 mA) to detect early signs of power supply degradation. Keeping spare modules in stock ensures quick replacement, aligning with the cost-benefit angle of minimizing production losses.
Compatibility & Integration
The ABB CI862 is specifically designed for the ABB AC 800M controller. It integrates TRIO/Genius I/O as native I/O, eliminating the need for additional protocol converters. The module supports up to four units on the CEX bus, allowing expansion to 1,000 I/O points. It also supports module redundancy, enhancing system availability.
Communication uses ABB's TRIO/Genius I/O protocol, ensuring seamless data exchange between the controller and remote I/O blocks. The CI862 is not used with HI Controller, and line redundancy is not supported. Verify that your existing system components are compatible before integration.
Buying Guide
Before purchasing the ABB CI862, confirm that your AC 800M controller firmware supports this module. Check the article number 3BUA000037R1 to ensure you receive the correct revision. Consider whether you need redundant modules for critical applications. For expert advice and genuine ABB parts, rely on PLC Source PRO as your trusted supplier.