Description

ABB CI858-1 3BSE018137R1

I. Product Overview

ABB CI858-1 3BSE018137R1 is a high-performance communication interface module, whose core function is to serve as a data communication bridge between the controller and external devices. This module achieves efficient data interaction with the AC 800M main controller via the CEX bus, and supports multiple industrial communication protocols at the same time. It can flexibly connect with various devices such as drives, remote I/O modules, sensors, actuators and upper monitoring systems, realizing real-time data transmission, remote monitoring, command issuing and collaborative device control.

With its core advantages including high-performance processing capability, multi-protocol compatibility, electrical isolation and strong anti-interference ability, it is widely used in various industrial fields such as manufacturing (automotive manufacturing, food and beverage), process control (chemical industry, oil and natural gas), power systems, intelligent transportation and industrial robot systems. The modular structure design supports hot swap function, and combined with the standard DIN rail mounting method, it greatly improves the convenience of on-site installation and operation & maintenance, effectively reduces the cost of system shutdown maintenance, and ensures the continuity and stability of the production process.

II. Functional Features

1. Multi-protocol Compatibility and Multi-mode Communication Capability

It supports a variety of mainstream industrial communication protocols, including Modbus TCP, Profibus DP, DriveBus, I/O Bus, PC Tool, etc., enabling seamless interoperability with different types of devices and meeting the multi-mode communication needs in complex industrial scenarios. It also integrates a 10M/100Mbps Ethernet interface, supports basic network protocols such as TCP, UDP, IP and ICMP, and can flexibly adapt the transmission mode according to the network environment to ensure the universality and stability of data transmission.

2. High-reliability Design and Electrical Protection

Equipped with a high-performance industrial-grade processor (designed based on Intel 82852GM+ICH4 chip) and on-board 512MB DDR 266MHz memory, it has strong data processing capability to support complex control requirements. The core is provided with electrical isolation function, which can effectively avoid the impact of external electrical interference on the system. Meanwhile, it is equipped with multiple electrical protection functions such as overvoltage protection, reverse connection protection and electrostatic protection, and has a built-in watchdog timer, which significantly improves the stability and reliability of system operation and can adapt to the harsh electromagnetic environment and voltage fluctuations in industrial sites.

3. Comprehensive Fault Diagnosis and Status Monitoring

It has a built-in complete status monitoring and fault diagnosis mechanism, which can real-timely monitor key information such as network connection status, data transmission rate, data packet error rate and module self-operation status. Diagnostic data is synchronously uploaded to the AC 800M main controller and upper monitoring system via the backplane bus. Meanwhile, the front panel of the module is equipped with multiple groups of LED status indicators, which intuitively display power status, operation status, network connection status, data transmission status and fault alarm information, facilitating on-site operation and maintenance personnel to quickly locate fault points (such as network interruption, port failure, protocol abnormality, etc.) and improve fault troubleshooting efficiency.

4. Flexible Expansion and Wide Adaptability

The modular structure design supports flexible system expansion. It can connect multiple devices via the CEX bus, and is fully compatible with ABB AC 800M series controllers and 800xA DCS systems (supporting V6.0.3.3 and above versions). It can also seamlessly connect with third-party standard-compliant industrial equipment and upper monitoring software (such as WinCC, iFIX, etc.). It provides rich user I/O interfaces, including 6 serial ports, 4 USB interfaces, 1 PS/2 KB/MS interface, CF card slot, etc., facilitating connection with various external devices. It supports hot swap function, allowing module replacement, maintenance and upgrade without stopping the system, thus effectively reducing the risk of system shutdown and operation & maintenance costs.

5. Convenient Configuration and Operation & Maintenance

Parameter configuration is supported via ABB CBF (Control Builder F) configuration software. The graphical operation interface simplifies the configuration process of IP address, subnet mask, gateway, communication protocol, redundancy strategy, data mapping, etc. The module has a built-in parameter storage unit, where the configured parameters can be permanently saved without loss even in case of power failure. It also supports backup and restoration of configuration parameters, and configuration parameters can be remotely viewed and modified through the upper system, further improving the convenience of operation and maintenance.

III. Technical Parameters

1. Basic Parameters

Model: CI858-1
Ordering Code: 3BSE018137R1
Brand: ABB
Product Type: Communication Interface Module
Applicable Systems: ABB AC 800M Controller, 800xA DCS System (supporting V6.0.3.3 and above versions)
Mounting Compatibility: Suitable for AC 800M controller rack and FLD distributed rack
Core Chip: Intel 82852GM+ICH4
Memory Specification: 512MB DDR 266MHz (maximum dynamic shared video memory: 64MB)

2. Communication Parameters

Supported Protocols: Modbus TCP, Profibus DP, DriveBus, I/O Bus, PC Tool, TCP, UDP, IP, ICMP, ARP
Communication Interfaces: 1×10M/100Mbps Ethernet interface (RJ45), 6 serial ports, 4 USB interfaces, 1 PS/2 KB/MS interface, CF card slot, CEX-Bus interface
Data Transmission Capability: High-speed real-time transmission
Number of Supported Slaves: Adjustable according to protocol type and system configuration
Maximum Concurrent Connections: ≥100

3. Power Supply Parameters

Power Supply Mode: Powered via CEX bus (+24V DC)
Power Consumption: Typical value 5W
Power Supply Protection: Equipped with overvoltage protection, reverse connection protection and electrostatic protection functions
Watchdog: Built-in watchdog timer
Redundant Power Supply: Support for CEX bus redundant power supply expansion

4. Environmental Parameters

Operating Temperature: -25°C ~ 60°C (wide temperature range for harsh environments)
Storage Temperature: -40°C ~ 85°C
Relative Humidity: 5% ~ 95% (non-condensing)
Protection Grade: IP20 (compliant with EN 60529 standard)
Altitude: ≤2000m (derating required if exceeded)
Pollution Degree: Degree 2 (compliant with IEC 61131-2 standard)
Electromagnetic Compatibility: Compliant with EN 55011/EN 55022 Class A and EN 61000-4 series standards

5. Physical Parameters

Mounting Method: Standard 35mm DIN rail mounting or plug-in rack mounting
Dimensions: 59mm (width) × 186mm (height) × 127mm (depth)
Net Weight: Approximately 0.7 kg
Housing Material: Industrial-grade flame-retardant ABS plastic
LED Indicators: Power Light (PWR), Run Light (RUN), Communication Activity Light (ACT), Fault Light (FAULT)
User I/O Pins: 94

IV. Working Principle

The core working logic of the ABB CI858-1 3BSE018137R1 module is "Controller Interaction - Protocol Conversion - Multi-mode Communication - Status Feedback and Fault Protection". It realizes efficient data interaction between the controller and various external devices through the collaboration of multiple links. The specific working process is as follows:

Controller Interaction: The module establishes a stable connection with the AC 800M main controller via the CEX bus, receives control commands and communication parameter configuration information issued by the controller, and feeds back the operation data and status information uploaded by external devices to the controller, realizing efficient two-way data interaction.
Protocol Conversion: The built-in dedicated protocol processing unit converts the internal data format of the controller into the standard format of industrial protocols such as Modbus TCP, Profibus DP, DriveBus, etc., to ensure that the data can be recognized by external devices or upper systems. At the same time, it reversely converts various protocol data uploaded by external devices into a format parsable by the controller, realizing compatible transmission of cross-device and cross-protocol data.
Multi-mode Communication: It establishes connections with various external devices through rich interfaces such as Ethernet interface, serial port and USB, completes real-time data transmission (such as controller's control commands for drives and sensor measurement data) according to the preset communication rate and data interaction cycle, supports TCP connection-oriented reliable transmission and UDP connectionless fast transmission, and can flexibly select the transmission mode according to the data type.
Status Feedback and Fault Protection: It real-timely monitors the communication link status, data transmission error rate, interface operation status and module self-status. When faults such as communication interruption, interface failure and data transmission abnormality are detected, it immediately issues an alarm via LED indicators and uploads fault information to the controller. The watchdog timer real-timely monitors the module operation status and automatically triggers the reset mechanism when an abnormality occurs, ensuring stable system operation and uninterrupted production control.

V. Common Fault Troubleshooting

Fault Phenomenon	Possible Causes	Troubleshooting Methods
Power Light (PWR) not on, module unresponsive	Backplane bus power supply fault, module not fully installed, internal power supply unit of the module damaged	Check whether the system power supply is normal and whether the CEX bus supply voltage is +24VDC; re-plug the module to ensure it is fully installed with good pin contact; if the above checks are normal but the module is still unresponsive, contact ABB official after-sales service to repair the internal power supply unit or watchdog timer function of the module
Ethernet LINK light not on, network connection failed	Damaged/loose Ethernet cable, switch port failure, incorrect IP address configuration	Check whether the Ethernet cable is tightly connected and replace the damaged cable; test whether the switch port is normal and replace it with a spare port; check the module's IP address, subnet mask and gateway configuration to ensure they match the network segment and have no conflicts
Data transmission interruption or severe packet loss	Excessive network load, poor cable shielding, electromagnetic interference, mismatched communication rate	Troubleshoot network load; if it exceeds 80%, optimize the network architecture (such as adding switches, splitting network segments); check the grounding condition of the cable shielding layer and replace unshielded cables with shielded ones; troubleshoot electromagnetic interference sources and take shielding protection measures; set the communication rate to auto-negotiation mode to ensure the module's rate matches that of the switch
Redundancy switching failure	Incorrect redundancy parameter configuration, standby port/network failure, abnormal synchronization link	Re-check and correct redundancy configuration parameters (such as switching conditions, delay time, etc.); check the status of standby ports, standby networks and switches to ensure the standby link is normal; check the wiring of the master-standby synchronization link and repair loose or damaged links
PROFINET IO slave fails to go online	Mismatched slave device address, protocol type or parameter configuration, slave device fault, incorrect data mapping relationship, poor interface connection	Check the address, protocol type and parameter configuration of the slave device to ensure they are consistent with the configuration; test the slave device individually to troubleshoot equipment faults; check the data mapping relationship (input/output byte length, address offset) and interface connection status, and correct configuration errors or connection problems