Introduction
Many industrial plants face a common pain point: they need to upgrade to modern automation systems but cannot afford to scrap legacy equipment. This creates compatibility issues that lead to production bottlenecks and high maintenance costs. The ABB CI855 communication interface offers a solution by bridging the gap between old and new. This case study examines how a chemical processing plant used the CI855 to connect its existing MasterBus 300 (MB300) controllers with a new System 800xA, achieving seamless peer-to-peer communication and significant operational improvements.
Customer Challenge
The plant operated multiple Advant Controller 410 and MasterPiece 200/1 units using the MB300 protocol. These controllers managed critical batch processes, but the plant wanted to adopt System 800xA for better data visibility and control. The challenge was that the new AC 800M controllers did not natively support MB300 communication. This forced operators to run two separate control networks, causing data silos and requiring manual data transfers between systems. Downtime averaged 12 hours per month due to communication errors, and maintenance costs for the legacy network exceeded $50,000 annually. The plant needed a reliable, cost-effective way to integrate both systems without replacing existing hardware.
The Solution
The plant deployed the ABB CI855 communication interface, which connects to the CEX-Bus via a TP853 baseplate. The CI855 implements the MB300 protocol, enabling direct peer-to-peer communication between the new AC 800M controllers and the existing MB300-based units. Key specifications that made this possible include a transmission speed of 10 Mbit/s and support for up to 200 Datasets per second, ensuring real-time data exchange. The interface also supports line redundancy for network reliability and hot swap capability for minimal downtime during maintenance. Installation was straightforward: the team mounted the CI855 on a DIN rail using the TP853 baseplate, which provides RJ45 connectors for two Ethernet ports. The entire deployment took less than two days, including configuration and testing.
Results and Benefits
After implementing the CI855, the plant achieved a 40% reduction in communication-related downtime, dropping from 12 hours to just 7 hours per month. The peer-to-peer communication eliminated the need for manual data transfers, saving operators 10 hours per week. Maintenance costs for the legacy network decreased by 60% as the CI855 reduced the load on aging hardware. The plant also benefited from clock synchronization across all controllers, improving batch consistency and product quality. Overall, the plant estimated a return on investment within eight months, driven by increased production uptime and lower operational expenses.
Key Takeaways
This case study demonstrates that the ABB CI855 is an effective solution for plants needing to integrate legacy MB300 systems with modern System 800xA. The interface's support for peer-to-peer communication, line redundancy, and hot swap makes it ideal for continuous process industries where uptime is critical. For plants considering a similar upgrade, the CI855 offers a low-risk, high-reward path to modernization without replacing existing controllers. Contact CtrlTechDaily to discuss how the CI855 can solve your specific integration challenges and help you achieve similar results.
Frequently Asked Questions
What types of applications is the CI855 best suited for?
The CI855 is ideal for applications requiring integration between ABB's System 800xA and legacy MB300-based controllers, such as Advant Controller 410, Advant Controller 450, and MasterPiece 200/1. It works well in continuous process industries like chemical, oil and gas, and power generation, where peer-to-peer communication and network redundancy are essential. The interface supports up to 12 units on the CEX bus, making it suitable for medium to large-scale installations.
How long does it take to deploy the CI855?
Deployment typically takes one to two days, including mounting the CI855 on a DIN rail using the TP853 baseplate, connecting the RJ45 Ethernet cables, and configuring the communication parameters. The hot swap feature allows for installation without shutting down the entire system, minimizing production disruption. Most plants report that operators can learn the basic configuration within a few hours, thanks to the intuitive setup process.
What support does CtrlTechDaily provide during implementation?
CtrlTechDaily offers pre-sales consultation to help you assess compatibility and plan the integration. During implementation, we provide technical documentation, including wiring diagrams and configuration guides, as well as remote support from experienced automation engineers. After deployment, we offer warranty coverage and ongoing technical support to ensure your system runs reliably. Contact us for a customized support plan tailored to your plant's needs.
