Product Overview
When upgrading an existing ABB Master or Advant OCS installation, the cost of rewiring field terminations can quickly erode the project budget. The ABB CI856 (3BSE026055R3) S100 I/O Software License for 800xA directly addresses this pain point by enabling reuse of the majority of existing I/O installations, including terminations and field wiring. This CI856 interface connects to the CEX-Bus through a base plate (TP856) and communicates with up to five S100 I/O racks, each holding up to 20 I/O boards. By preserving the existing cabling infrastructure, the CI856 reduces material costs, labor hours, and downtime, delivering a measurable ROI on every upgrade project.
Technical Specifications Breakdown
The CI856's specifications directly influence both performance and total cost of ownership. Key parameters include:
- Communication protocol: ABB's S100 I/O – this proprietary protocol ensures deterministic data exchange with S100 I/O units, eliminating the need for protocol converters and their associated costs.
- Max units on CEX bus: 12 – this capacity allows the CI856 to coexist with other CEX-bus modules, maximizing the processor's I/O density without requiring additional controllers.
- 24 V consumption typ.: 120 mA – low power draw reduces strain on the system power supply and lowers energy costs over the product's lifespan.
- Hot Swap: Yes – modules can be replaced without powering down the system, minimizing production downtime and maintenance labor expenses.
- Temperature, Operating: 0 to +55 °C (+32 to +131 °F) – the wide operating range suits industrial environments without requiring costly climate-controlled enclosures.
- Protection class: IP20 according to EN60529, IEC 529 – provides adequate protection for cabinet-mounted installations, avoiding the premium cost of higher-rated enclosures.
- Weight (including base): 700 g (1.5 lbs) – lightweight design simplifies handling and reduces shipping costs.
Industry Applications
Process Industry Retrofit: A chemical plant running an ABB Master system needs to migrate to 800xA without replacing thousands of field terminations. The CI856 connects directly to existing S100 I/O racks, preserving the wiring and reducing the migration budget by up to 40%. The hot swap feature allows I/O board replacement during planned maintenance windows, avoiding unplanned shutdowns.
Power Generation Expansion: A power station adds monitoring points for new environmental sensors. Using the CI856, engineers connect up to five I/O racks (100 I/O boards total) to the AC 800M controller. The low 120 mA consumption per module keeps the overall power budget low, and the G3 corrosion protection (per ISA 71.04) ensures reliable operation in harsh turbine hall environments.
Installation & Setup Guidance
Mount the CI856 on a DIN rail using the TP856 base plate, which houses a ribbon connector for the bus extender boards in S100 I/O racks. The CI856 draws power from the processor unit via the CEX-Bus, so no external power supply is needed – this simplifies wiring and reduces installation costs. Connect up to five S100 I/O racks using the 36-pin Miniribbon connector. The code locking device prevents mounting incompatible components, avoiding costly miswiring errors. Ensure the operating temperature stays within 0 to +55 °C and that the enclosure provides IP20 protection.
Maintenance & Reliability
The CI856's hot swap capability directly reduces maintenance costs: technicians can replace a faulty I/O board without stopping production. The G3 corrosion protection extends service life in aggressive environments, lowering replacement frequency. Periodic inspection of the ribbon cable and connector integrity is recommended – a simple visual check can prevent intermittent communication faults. Because the module is powered via CEX-Bus, there are no separate power supply components to fail, further improving reliability and reducing spare parts inventory.
Compatibility & Integration
The CI856 is designed exclusively for ABB's S100 I/O protocol and works as a master on the CEX-Bus. It is used together with HI Controller and supports up to 12 units on the CEX bus. The module is compatible with ABB AC 800M controllers and integrates seamlessly into the 800xA system. Line redundancy and module redundancy are not supported, so for high-availability applications, consider redundant CI856 modules or a redundant AC 800M configuration. The CI856 does not require additional external power, simplifying integration into existing cabinets.
Selection Guide & Purchasing Advice
Before ordering the CI856 (3BSE026055R3), verify that your existing S100 I/O racks are compatible and that you have the TP856 base plate. Confirm that your AC 800M processor has an available CEX-Bus slot. The CI856 is a software license for 800xA – ensure your system software version supports this module. SpareTechPLC stocks the CI856 and can advise on lifecycle status and availability. Contact us to confirm stock and lead times before placing your order.
Frequently Asked Questions
Q: Can the CI856 be used with non-ABB controllers?
A: No. The CI856 uses ABB's proprietary S100 I/O protocol and is designed exclusively for ABB AC 800M controllers on the CEX-Bus.
Q: How many S100 I/O boards can I connect to one CI856?
A: Up to five I/O racks, each holding up to 20 I/O boards, for a maximum of 100 boards per CI856.
Q: Does the CI856 require an external power supply?
A: No. The CI856 is powered via the CEX-Bus from the processor unit, consuming only 120 mA at 24 V.
Q: What is the benefit of the code locking device?
A: It prevents mounting incompatible I/O boards, protecting your system from damage and reducing commissioning errors.
Q: Is the CI856 suitable for outdoor installation?
A: No. Its IP20 protection rating requires installation in a clean, dry cabinet. The operating temperature range is 0 to +55 °C.
