Product Core Brief

• Full Model: CI855K01
• ABB Official Article Code: 3BSE018106R1
• Kit Composition: Complete factory integrated set = CI855 MB300 communication module + matched TP853 DIN rail termination baseplate, single part number contains both components
• Brand: ABB Control Systems
• Series: CEX expansion bus communication module for AC800M / System 800xA DCS
• Core Function: Proprietary MasterBus 300 (MB300) gateway via controller CEX bus; dual independent RJ45 Ethernet ports realize MB300 media redundancy, realize peer-to-peer cross-system data exchange between new AC800M 800xA stations and legacy Advant OCS (AC410/AC450/MasterPiece200) DCS, support Dataset real-time cyclic data, clock synchronization, cross-controller peer communicationABB.
• Product Type: Slide-in CEX MB300 interconnection communication full kit (module + TP853 baseplate)
• Key Specs: Dual 10Mbps RJ45 Ethernet | MB300 proprietary protocol | Network media redundancy | Official IEC hot-swap certified | RoHS compliant | Max 12 units per AC800M CEX rackNote: Active maintenance spare, core hardware for hybrid old/new ABB DCS plant renovation; only communicates via ABB exclusive MB300, not universal Modbus TCP/Profinet/IP.

Core Kit Definition

• CI855K01 / 3BSE018106R1: Complete kit = CI855 communication board + TP853 base with dual RJ45
• Separate CI855 module only: No baseplate, need to order TP853 (3BSE018126R1) individually

 

Key Technical Specifications

• Power supply: Powered entirely by AC800M internal CEX backplane, typical current 150mA@24VDC, max power dissipation ~3.6W, no external auxiliary power required
• Communication Protocol: Exclusive ABB MasterBus 300 (), legacy Advant OCS backbone bus protocol
• Transmission speed: Fixed 10 Mbps half-duplex Ethernet, up to 200 Datasets per second real-time data throughput
• Physical interface: TP853 base integrates two independent RJ45 8P8C ports for redundant trunk wiring; dual separate cable paths for media fault auto-switchover
• Redundancy capabilities
  1. media line redundancy: Dual Ethernet independent links, automatic primary/secondary failover
  2. Support full system CPU+CEX module redundant architecture paired with second CI855K01 kit
• Galvanic isolation: 1500 VAC dielectric separation between Ethernet field side and controller CEX logic circuit
• Supported core industrial functions
  1. Certified Hot Swap: Replace module online without full controller shutdown
  2. Cross-system peer-to-peer communication: Bridge AC800M 800xA and Advant AC410/AC450/MasterPiece legacy racks
  3. Dataset cyclic real-time data exchange for inter-controller control signal & process value transmission
  4. System-wide clock synchronization across hybrid DCS plant
  5. Full module & link diagnostics: Ethernet link loss, cable short, CEX bus fault centralized to HMI
• PCB coating: ISA-S71.04 G3 industrial conformal coating for mild corrosive power, pulp and chemical plant cabinet environments
• Status indicators: Module front multi-color LEDs: PWR, CEX RUN, BUS FAULT, CH1/CH2 communication status
• Mechanical lock: TP853 base with fixed alpha mechanical lock, prevents incompatible CEX communication modules forced insertion damage
• Operating ambient: 5 ℃ ~ +55 ℃ continuous duty; compact vertical narrow racks limited to 0 ~ +40 ℃
• Storage range: -40 ℃ ~ +70 ℃, non-condensing RH 5–95%
• Certifications: CE, UL508, ATEX II 3G Ex nA IIC T4 Gc Zone 2, cULus Class I Div 2 Groups A-D; RoHS 2 / WEEE compliant, marine DNV-GL/LR/BV certifiedABB
• Overall dimensions (module + base integrated set): W59 mm × H185 mm × D127.5 mm; total weight ~700gABB

 

Product Introduction

CI855K01 (3BSE018106R1) is the exclusive MasterBus300 interconnection gateway full kit for AC800M / System 800xA DCS, consisting of CI855 communication board and matching DIN rail baseplate.It inserts into the controller rack’s CEX expansion bus, the only official hardware to realize seamless data interconnection between modern 800xA control stations and old Advant OCS DCS (AC410/AC450/MasterPiece200) running backbone bus, widely used in plant upgrade, hybrid DCS coexistence renovation projectsABB.Dual independent RJ45 Ethernet ports on base realize full media redundancy, eliminating single cable failure risk for inter-rack safety control signals. Galvanic isolation suppresses ground-loop EMI noise from long cross-cabinet trunk cables and variable frequency drives, avoiding intermittent cross-system process value freezing or link dropout.Native hot-swap certification minimizes maintenance downtime; built-in Dataset transmission and clock sync unify all new/old controller timebase and interlock control data. Up to 12 complete CI855K01 sets can be installed in one rack to build multi-area hybrid DCS interconnection backbone.

Distinction vs Other CEX Communication Modules

1. CI855K01: proprietary dual Ethernet, cross Advant/800xA interconnection, not universal industrial Ethernet
2. CI854BK01: Profibus DP-V1 master for S800/S900 I/O, Profibus protocol
3. CI853: Dual RS232/485 serial Modbus/COMLI gateway
4. CI856: Profinet IO Ethernet master, universal industrial Ethernet

 

QA & Testing SOP

1. Incoming Inspection: Cross-reference serial numbers and 3BSE018106R1 full kit part code against ABB spare databases. Inspect dual RJ45 pin integrity, alpha lock matching, full front LED bank functionality, complete matched CI855 module + base assembly and intact factory anti-static vacuum packaging to filter counterfeit stock.
2. Live Bench Testing: Install full kit inside test rack paired with PM865 CPU simulator and legacy Advant AC450 simulator. Run continuous 24-hour cyclic Dataset communication testing, simulate primary trunk disconnection, Ethernet short-circuit to validate automatic redundant link failover and diagnostic flag timing.
3. Electrical Isolation Test: Use 500V Megger to measure insulation resistance between Ethernet field circuit and CEX bus logic; pass threshold ≥10 MΩ. Inject 50Hz differential ground-loop noise to confirm no random cross-controller communication loss.
4. Firmware & Configuration Backup: Record factory default node address, Dataset mapping and redundancy parameters via Control Builder M engineering software. Capture high-resolution photos of dual pinout and wiring layout for field commissioning reference.
5. Final Packaging: Fit plastic dust caps over both Ethernet ports; keep module and baseplate matched as one complete set. Place full assembly inside foam-lined anti-static shielding bag, affix dated QC pass label before sealing in original factory carton.

 

Installation Pitfalls & Guide

❗Firmware Mismatch Risk: controller firmware older than v5.0.0 lacks CEX register mapping for dual-link redundancy and cross-system Dataset exchange logic. Post-replacement, inter-controller data loss and intermittent LINK FAULT alarms occur. Remediation: Upgrade PM86x CPU firmware to V5.0.0 or newer before installing the kit.❗Protocol Limitation Warning: CI855 only supports exclusive ABB protocol, cannot be used as Modbus TCP/Profinet/IP general Ethernet gateway; universal industrial Ethernet communication requires CI856 module.❗Redundancy Cabling Error Risk: Dual Ethernet trunk lines must run separate physical cable trays to achieve true fault tolerance; routing both cables inside one tray completely negates media redundancy protection during tray damage events.❗Ethernet Termination Rule Violation: trunk requires end termination resistor only on the farthest Advant legacy controller node; duplicate or missing termination creates signal reflection, persistent data jitter and random link offline faults.❗Hot-Swap Precondition: Though certified hot-swap, pause all cross-controller Dataset logic blocks in Control Builder M before module extraction to avoid temporary interlock signal loss.❗CEX Bus Quantity Limit: Max 12 full communication kits per single controller rack, exceeding this limit triggers CEX bus overload fault codes.❗ESD Damage Risk: Ungrounded handling exposes dual Ethernet transceiver and CEX bus logic traces to static discharge from dry control room air. Field records show unprotected handling burns both communication channels simultaneously; full hybrid DCS interconnection downtime labor cost exceeds $1,480. Remediation: Place anti-static mat under controller rack, wear grounded wrist strap, touch bare cabinet chassis ground for 3 seconds before handling the module/baseplate assembly.

4-step Replacement Procedure (Support Hot-Swap)

1. Pre-install Preparation: supports certified hot-swap (rack 24V power remains energized). Photograph dual redundant trunk wiring layout, node address mapping and Dataset interlock configuration in Control Builder M; pause all cross-controller cyclic Dataset logic blocks to suspend inter-system data exchange.
2. Removal: Unlatch base retention clip, slide the old module upward out of the base slot, disconnect dual trunk cables; store old module inside static-safe sleeve.
3. Installation: Take new complete kit, insert factory-matched module fully into the base and lock retention latch; reconnect dual redundant trunk cables to matching CH1/CH2 ports, install end-of-line termination resistor on the farthest legacy Advant controller node.
4. Power-on Commissioning Test: Rack power remains energized (hot-swap permitted). Verify front PWR, RUN and CH1/CH2 COM LEDs illuminate steady green, perform full network node scan to confirm all new/old DCS controllers communicate correctly, test primary trunk cable disconnection to validate fast automatic redundant link failover function before re-enabling cross-system interlock automatic control.

 

FAQ

Q1: Can be hot-swapped while the controller rack remains powered?A: Yes, carries official ABB IEC hot-swap certification for standard control room environments. Only pause cross-controller Dataset logic beforehand to avoid temporary interlock signal loss, no full rack power isolation required.

Q2: Does this communication full kit carry original OEM factory warranty?A: ABB original factory production warranty follows standard lifecycle coverage for active maintenance hardware. All new original kits pass full in-house bench QA testing and carry a 12-month internal stock replacement warranty, limited to manufacturing defects detected during validation testing.

Q3: Can other CEX communication modules (CI854BK01/CI853) replace for interconnection?A: No. CI854 series is Profibus DP master, CI853 is serial RS485 gateway; neither supports proprietary protocol, zero functional interchangeability, full bus architecture rework required if substitution.

Q4: What minimum CPU firmware version enables full dual-link redundancy and cross-system Dataset exchange?A: PM86x controller firmware v5.0.0 or newer. Older firmware cannot process redundant link switchover and cross-controller real-time Dataset data.

Q5: Will node address, Dataset mapping and redundancy configuration persist after kit replacement?A: All bus interconnection configuration data resides in CPU non-volatile memory; no local parameter storage on module hardware. No full reconfiguration required post-swap, only complete network node scan and redundancy failover verification test.

Q6: Is compatible with standalone S800/S900 I/O racks without Advant legacy controllers?A: It can be installed on rack alone, but without legacy Advant nodes connected, the module has no practical communication function; it is exclusively designed for hybrid new/old DCS interconnection scenarios.

Q7: What is the difference between (3BSE018106R1) and standalone module?A: 3BSE018106R1 () is a complete factory kit including communication module + baseplate; standalone only contains the PCB board alone, baseplate (3BSE018126R1) must be ordered separately.