Description:

The ABB CI858K01 3BSE018135R1​is a high-performance PROFIBUS DP-V1 master communication interface module designed for ABB’s AC 800M programmable logic controller(PLC).This module enables the AC 800M to act as the master on a PROFIBUS DP network,facilitating high-speed,deterministic data exchange with a wide array of field devices such as remote I/O,variable frequency drives,motor starters,and instrumentation.It serves as a critical gateway for integrating decentralized peripherals into the centralized control architecture.

Application Scenarios:

In a large automotive paint shop,hundreds of variable frequency drives(VFDs)controlling conveyor belts,fans,and pumps need to be precisely synchronized.A manufacturer faced challenges with hardwired control’s complexity and lack of diagnostic capabilities.By implementing the CI858K01​PROFIBUS DP master module in their AC 800M controllers,they created a robust digital network.Each drive became a node on the PROFIBUS DP network,with the CI858K01​cyclically exchanging setpoints,actual values,and status information.This enabled precise speed synchronization of conveyors for smooth vehicle movement and allowed operators to monitor drive health and receive immediate fault notifications.The application of the CI858K01​reduced wiring by 60%,slashed commissioning effort,and provided the diagnostic depth to cut drive-related downtime by 45%.

Parameter:

Main Parameters

Value/Description

Product Model​

CI858K01​

Manufacturer Order Code​

3BSE018135R1​

Manufacturer​

ABB

Product Category​

PROFIBUS DP-V1 Master Communication Interface

Compatible Controller​

ABB AC 800M(e.g.,PM861,PM863,PM865)

Communication Protocol​

PROFIBUS DP per IEC 61158/EN 50170,Version DPV1

Data Transfer Rates​

9.6 kbps to 12 Mbps,auto-detection

Physical Interface​

2 x SUB-D 9-pin ports(RS-485)

Number of Connections​

Up to 122 slaves(depending on data volume)

Diagnostic Capabilities​

Comprehensive slave diagnostics,module status LEDs

Redundancy Support​

Yes,for high-availability systems

Configuration​

Via ABB Control Builder engineering tool

Power Consumption​

Typical 1.5W from controller baseplate

Technical Principles and Innovative Values:

The ABB CI858K01 3BSE018135R1​translates the AC 800M’s internal process data into the PROFIBUS DP telegram structure,managing network traffic with high efficiency and reliability.

Innovation Point 1:PROFIBUS DP-V1 Master Functionality.​The CI858K01​operates as a DP-V1 master,which extends the standard DP protocol.While DPV0 handles cyclic data exchange for control,DPV1 adds acyclic communication.This allows the AC 800M to perform non-time-critical tasks,such as reading/writing parameters to intelligent field devices or reading detailed diagnostic records,without interrupting the real-time control cycle.This is essential for advanced device configuration and asset management.

Innovation Point 2:Integrated Network Diagnostics and Redundancy.​The module features comprehensive diagnostic capabilities visible in Control Builder.It can detect and report slave failures,network segment breaks,and configuration errors.For mission-critical applications,the CI858K01​supports redundant configuration.Two modules can be installed,with one acting as a hot standby.If the primary module or its network fails,the secondary takes over seamlessly,ensuring continuous network operation and maximizing system availability.

Innovation Point 3:Seamless Engineering Integration.​The CI858K01​is not a standalone gateway;it is fully integrated into ABB’s Control Builder engineering platform.The hardware configuration,including the setup of the PROFIBUS DP network with all its slaves,is done within the same project as the controller logic.The tool handles the import of slave device descriptions(GSD files),making the I/O data from each slave device appear as directly mapped variables in the controller,simplifying programming and reducing integration time.

Application Cases and Industry Value:

Case Study:Pharmaceutical Batch Plant Upgrade.​A pharmaceutical manufacturer upgraded its legacy distributed control system(DCS)to an ABB Ability™800xA platform with AC 800M controllers.A key challenge was integrating dozens of existing intelligent weighing modules and Coriolis flowmeters from various vendors scattered across the process area.

The solution utilized the CI858K01​PROFIBUS DP master modules.Each field device with a PROFIBUS DP interface was connected to the network.The CI858K01​modules not only read the cyclic process data(weight,flow rate)with high determinism but also used the acyclic DPV1 services to read device-specific diagnostics and write configuration parameters remotely.This eliminated the need for technicians to physically access devices in classified areas for minor adjustments.The project resulted in a 30%reduction in system integration time compared to a conventional I/O approach and provided complete asset visibility,contributing to the plant’s compliance with stringent FDA data integrity requirements(21 CFR Part 11).

Related Product Combination Solutions:

The CI858K01​is a key component in a networked control architecture.Essential related products include:

AC 800M Controller(e.g.,PM865):​The high-performance CPU that houses the CI858K01​module and executes the control logic using data from the PROFIBUS network.

PROFIBUS DP Slaves:​The field devices connected to the network.Examples include:

Remote I/O Stations(e.g.,ABB S800 I/O with PROFIBUS interface):​For distributing digital and analog I/O points.

Variable Speed Drives(e.g.,ABB ACS880 with FENA-01 adapter):​For controlling motors.

Motor Protection Relays(e.g.,ABB CM-PPS):​For intelligent motor management.

PROFIBUS Network Components:​PROFIBUS cables​and connectors​with built-in terminators are required to build the physical network.

Control Builder Plus:​ABB’s unified engineering software for configuring the AC 800M,the CI858K01​module,and the entire PROFIBUS DP network.

Other Communication Interfaces for AC 800M:

CI854A:​PROFIBUS DP Slave module,allowing the AC 800M to act as a slave to a higher-level PLC.

CI871:​PROFINET IO Controller module for modern Ethernet-based integration.

CI858A:​Foundation Fieldbus H1 interface for process instrumentation.

SD832:​Power supply module for the AC 800M rack,providing power to the controller and all communication modules like the CI858K01.

Installation,Maintenance,and Full-Cycle Support:

Installation of the ABB CI858K01 3BSE018135R1​is straightforward for trained personnel.The module is designed to be plugged into a free communication slot on the AC 800M controller’s baseplate.The PROFIBUS network is connected via the two standardized 9-pin SUB-D ports,which facilitate the creation of a redundant bus topology or the use of a drop cable.Proper network termination at both ends of the segment is critical for signal integrity and is enabled via switches on the PROFIBUS connectors.

Routine maintenance is primarily software-based,leveraging the module’s diagnostic capabilities.The status of the CI858K01​and all connected slaves can be monitored from the 800xA operator station or Control Builder.The module’s health is indicated by LEDs.In a redundant system,a module can be replaced during operation.In a non-redundant system,replacement requires a planned shutdown.The configuration is stored in the controller,so a new CI858K01​module is recognized and starts operating once inserted.We provide end-to-end support,from network design and GSD file management to troubleshooting,spare parts,and firmware updates,ensuring your PROFIBUS DP network remains a reliable backbone for your automation system.