ABB 3BSE018135R1 (CI858K01) Communication Interface Module
1. 3BSE018135R1 Product Overview
ABB 3BSE018135R1, commonly known as CI858K01, is a high-speed communication interface module designed for ABB’s AC 800M distributed control system (DCS). Acting as a “data bridge” between the DCS controller and industrial networks, it enables fast and reliable data exchange between the control system and external devices—such as HMIs, SCADA systems, and third-party controllers. Widely used in power plants, chemical factories, and manufacturing lines, it ensures seamless coordination of all system components.
Think of it as a “multilingual translator” for industrial equipment: Different devices in a factory often use different communication protocols (like Profinet, Modbus, or Ethernet/IP). The CI858K01 converts these protocols into a language the AC 800M controller can understand, and vice versa. For example, in a chemical plant, it collects production data from Modbus-based sensors and sends it to the AC 800M controller, while also transmitting the controller’s control commands to Profinet-enabled valves—ensuring smooth information flow across the entire system.
Key advantages that make it a core component in industrial communication:
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Multi-Protocol Support: Natively supports Profinet, Ethernet/IP, and Modbus TCP/IP—eliminating the need for additional protocol conversion modules.
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High-Speed Data Transfer: Delivers data transmission rates up to 1Gbps, ensuring real-time control signals and production data are exchanged without delays.
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Seamless DCS Integration: Plugs directly into ABB AC 800M controller racks, with automatic recognition by the DCS—no complex configuration for basic operation.
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Robust Stability: Built with industrial-grade components, it resists electrical interference and operates stably in harsh factory environments with temperature fluctuations and vibration.
Practical example: In a wastewater treatment plant using ABB AC 800M DCS, 3 CI858K01 modules manage communication for 50+ devices. One module connects to Modbus-based flow sensors to monitor water throughput, another links to Ethernet/IP-enabled pumps for control, and the third transmits aggregated data to the central SCADA system. If a sensor’s data changes, the module sends the update to the controller in less than 1ms, allowing the system to adjust pump speed immediately.
2. 3BSE018135R1 Key Technical Specifications
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Specification Category
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Details
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Typical Applications
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Power plants, chemical processing, wastewater treatment, and manufacturing DCS systems
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Supported Protocols
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Profinet RT/IRT, Ethernet/IP, Modbus TCP/IP, ABB AC 800M Internal Bus
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Communication Performance
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Max data rate: 1Gbps; Latency: ≤1ms for real-time (RT) signals; ≤100μs for isochronous real-time (IRT) signals
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Network Interfaces
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4 x Gigabit Ethernet ports (RJ45); 1 x internal DCS bus port (for AC 800M connection)
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Data Processing Capacity
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Supports up to 1000 I/O data points; Max 50 concurrent communication connections
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Power Supply
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24V DC ±10% input; Power consumption: ≤15W (full load)
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Environmental Conditions
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Operating temperature: 0℃–60℃; Relative humidity: 5%–95% (no condensation); Vibration resistance: 2G (10-500Hz)
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Physical Specifications
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Dimensions: 140mm×100mm×30mm (L×W×H); Weight: ~380g; Mounting: ABB AC 800M standard rack
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Certifications
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UL, CE, IEC 61131-2, ISO 9001, ATEX (for hazardous areas)
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3. System Integration Guide
Integrating the CI858K01 (3BSE018135R1) into the ABB AC 800M DCS is straightforward—focus on physical installation, network wiring, and protocol configuration. Follow these steps for reliable communication:
3.1 Integration Steps (with Safety Tips)
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DCS Power Off: Shut down the AC 800M controller rack and disconnect the main power. Hang a “Maintenance in Progress” sign to prevent accidental startup.
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Module Installation: Insert the CI858K01 into the dedicated communication slot of the AC 800M rack (labeled “Comm Interface”). Push until it clicks to ensure a tight connection with the rack backplane.
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Wiring Connections: Network wiring: Connect external devices to the module’s Ethernet ports—e.g., link Profinet valves to Port 1, Modbus sensors to Port 2, and SCADA system to Port 3. Use shielded Cat6 cables for noise reduction.
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Power wiring: Connect the 24V DC power cable to the module’s power terminal—double-check polarity to avoid damage.
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Grounding: Connect the module’s ground terminal to the DCS rack ground (ground resistance ≤4Ω) for anti-interference.
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Protocol Configuration: Use ABB Control Builder M software to set up communication parameters: Assign IP addresses to each Ethernet port (e.g., Port 1: 192.168.1.10, Port 2: 192.168.2.10) to avoid network conflicts.
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Define protocol for each port (e.g., set Port 1 to Profinet RT, Port 2 to Modbus TCP/IP).
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Map I/O data points: Link sensor data (e.g., flow rate) and control signals (e.g., valve open/close) to the AC 800M controller’s internal database.
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Test & Verification: Restore power to the DCS rack—check the module’s “Online” LED (green = normal communication, red = fault).
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Trigger a sensor (e.g., a flow sensor) and confirm the data appears in Control Builder M within 1ms.
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Send a control command from the DCS (e.g., “open valve 1”) and verify the valve responds correctly via the module’s Port 1.
3.2 Daily Maintenance Tips
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Daily Check: Monitor the module’s port LEDs (steady green = active connection, flashing green = data transmission) and DCS HMI—ensure no communication errors are reported.
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Weekly Inspection: Visually check Ethernet cables for damage (e.g., frayed wires) and ensure connectors are tight (vibration can loosen them).
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Monthly Cleaning: Use compressed air (low pressure) to clean dust from the module’s ventilation holes and Ethernet ports—preventing overheating and connection issues.
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Quarterly Backup: Save the module’s configuration settings (via Control Builder M) to a secure storage device—facilitating quick recovery if the module fails.
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Fault Handling: If communication fails, first check the Ethernet cable and IP address settings. If normal, use the software’s diagnostic tool to identify protocol mismatches or port faults.
4. Recommended ABB Related Models (Different Series)
ABB offers a comprehensive range of DCS components and industrial control products. Below are practical models from different ABB series to meet diverse system needs:
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Model
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Series
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Key Features & Application Scenarios
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ABB PM864K01 (3BSE042236R1)
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AC 800M Controller
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High-performance DCS controller. Pairs with CI858K01 to form the core of AC 800M system—handles complex control logic for power plant boilers or chemical reactors.
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ABB CI854A (3BSE022465R1)
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Communication Interface
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Serial communication module (RS-485/RS-232). Ideal for connecting legacy devices (e.g., old pressure gauges) to the AC 800M DCS, complementing CI858K01’s Ethernet capabilities.
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ABB AI810 (3BSE032466R1)
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Analog I/O Module
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8-channel analog input module. Collects temperature, pressure, and flow signals from sensors, then sends data to the AC 800M controller via the CI858K01 module.
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ABB DO810 (3BSE020520R1) View more
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Digital I/O Module
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16-channel digital output module. Executes controller commands (e.g., turn on pumps, activate alarms) after receiving signals via the CI858K01.
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ABB HMI800 (3BSE050094R1)
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HMI Series
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10-inch touchscreen HMI. Connects to CI858K01 to display real-time data and allow manual control—intuitive for operators in factory control rooms.
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ABB AC500-S (3BSE038416R1)
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AC500 PLC Series
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Compact PLC for small-scale systems. Communicates with AC 800M DCS via CI858K01—suitable for auxiliary systems like factory lighting or conveyor belts.
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