ABB CI857K01 3BSE018144R1 Genuine Spare Part

Description

Application Scenarios:

In a large pharmaceutical plant, a new high-speed packaging line equipped with dozens of third-party servo drives, barcode scanners, and conveyor controllers needs to be integrated into the existing ABB 800xA Distributed Control System (DCS). Each device communicates via PROFIBUS DP. The ABB CI857K01​ module provides the perfect solution. Installed in an S800 I/O station connected to the AC 800M controller, it serves as the central PROFIBUS master. The module’s high data throughput and deterministic communication allow the DCS to send precise motion commands and receive real-time status and diagnostic data from all devices on the network simultaneously. This centralizes control, simplifies programming, and enables advanced diagnostics, turning a complex multi-vendor system into a cohesive, manageable, and highly efficient automated line, all orchestrated through the reliable CI857K01​ communication link.

Technical Principles and Innovative Values:

Innovation Point 1: Deep System Integration and High-Performance Processing.​ The ABB CI857K01​ is not an external gateway; it is a native, high-speed processor module within the S800 I/O rack. It connects directly to the controller via the backplane’s high-speed bus, offering extremely low latency and deterministic data transfer. This seamless integration allows the controller to access all PROFIBUS slave data as if it were local I/O, enabling tight, real-time control loops critical for process and motion control applications, far surpassing the performance of external protocol converters.

Innovation Point 2: Robust Redundancy and High Availability.​ Designed for mission-critical applications, the CI857K01​ supports hardware redundancy. Two modules can be configured as a redundant master pair. In the event of a failure in the primary master, the standby module takes over the PROFIBUS network control within a few bus cycles, ensuring uninterrupted communication. This failover capability, combined with the module’s industrial-grade design, provides the high availability required in continuous process industries where network downtime translates directly to production loss.

Innovation Point 3: Advanced Diagnostics and Simplified Engineering.​ The module provides comprehensive diagnostic capabilities at the module, network, and slave device levels. Faults are reported directly to the controller’s alarm system. Configuration is streamlined within ABB’s Control Builder engineering environment, where the network is graphically configured by importing slave GSD files. This integration simplifies network setup, commissioning, and troubleshooting, reducing engineering effort and minimizing startup and maintenance time.

Application Cases and Industry Value:

Case Study:​ Modernization of a Cement Plant Kiln Drive System. A cement plant upgraded its critical kiln drive from an old DC system to a new AC drive with a PROFIBUS interface. The existing control system was an ABB Advant Controller. The integration challenge was solved by adding an S800 I/O station with an ABB CI857K01​ PROFIBUS master module. The CI857K01​ connected to the new drive, allowing the legacy controller to seamlessly send speed setpoints and receive motor temperature, current, and status feedback. The advanced diagnostics from the drive, now visible in the control room, enabled predictive maintenance, preventing a potential bearing failure. The project engineer highlighted that the CI857K01’s reliability and ease of integration allowed them to modernize a single drive without overhauling the entire control system, saving significant capital and achieving a rapid return on investment through improved energy efficiency and reduced unplanned downtime.

Related Product Combination Solutions:

The ABB CI857K01​ is the communication core of a system. A typical integration setup includes:

ABB S800 I/O Baseplate (e.g., TU833 or TU839):​ The mounting unit that provides power and data connectivity for the CI857K01​ and other I/O modules.

ABB AC 800M Controller (e.g., PM802F, PM803F):​ The main controller that utilizes the CI857K01​ as its PROFIBUS communication interface.

ABB CI858 Module:​ An Ethernet TCP/IP communication interface module, showing the modularity for different network needs within the same S800 system.

ABB TA521 Terminal Assembly:​ The connection kit for the PROFIBUS network cable to the CI857K01’s D-Sub port.

PROFIBUS DP Slaves:​ This includes a vast array of devices such as Siemens ET 200SP​ remote I/O stations, ABB ACS880/ACS580​ variable speed drives, SICK safety laser scanners, and Endress+Hauser Proline​ flowmeters, all communicating with the DCS via the CI857K01.

ABB Control Builder Professional:​ The engineering software used to configure the hardware, program the controller, and set up the CI857K01’s PROFIBUS network.

Installation, Maintenance, and Full-Cycle Support:

Installation & Commissioning:​ Installing the ABB CI857K01​ is straightforward. The module is inserted into a compatible slot on the S800 baseplate. The PROFIBUS network cable is connected to its 9-pin port with proper termination. The key setup is performed in software using Control Builder: the module is added to the hardware configuration, its PROFIBUS address and network parameters are set, and the GSD files for all connected slave devices are imported to define the data exchange structure (I/O mapping).

Maintenance & Fault Handling:​ The module is designed for high reliability with no routine maintenance required. Its status is continuously monitored via LED indicators and the controller’s diagnostic suite. In a redundant configuration, a failed primary module can be hot-swapped. In a single configuration, replacement involves a controlled shutdown of the I/O station, module swap, and power-up, after which the controller will recognize and configure the new unit automatically based on the stored project.

Full-Cycle Support:​ We provide end-to-end support for the ABB CI857K01 3BSE018144R1. This includes sourcing genuine, factory-tested or certified refurbished units. Each module undergoes rigorous functional testing, including communication and redundancy tests where applicable. We offer technical guidance on configuration and integration, and back our products with a warranty. Our expertise ensures you receive a reliable component and the support needed for seamless integration and long-term operation of your PROFIBUS network.

Contact us for the genuine ABB CI857K01 3BSE018144R1 module and professional support for your industrial communication and control system integration projects.