Product Core Brief
- Model: CI858K01 (3BSE018135R1)
- Brand: ABB
- Series: CEX Expansion Bus for AC800M / System 800xA DCS
- Core Function: Acts as DriveBus fiber master to sync ABB multidrive stacks over optical cabling.
- Product Type: Complete communication kit (CI858 module + TP853 DIN rail termination base)
- Key Specs: 8 Mbps fiber speed | Max 24 connected drives | 500 V galvanic isolation | Condition: New Original (New Surplus)
Product Introduction
ABB 3BSE018135R1 delivers dedicated fiber-optic master control for ABB multidrive systems connected to AC800M controllers. It eliminates copper cable EMI from high-power variable frequency drives.This unit differs from Profibus or serial CEX modules by supporting sub-10 ms synchronization for tension and speed loops. A single rack accepts two kits to scale production lines up to 48 independent drive axes.
Key Technical Specifications
| Parameter | Value |
|---|---|
| Auxiliary Power Source | AC800M internal CEX bus (no external 24 V feed) |
| Typical Power Dissipation | 3.4 W |
| DriveBus Transfer Rate | 8 Mbps optical differential signaling |
| Maximum Drives Per Kit | 24 ACS600/ACS800/ACS880 series inverters |
| Max Per AC800M Rack | 2 units |
| Galvanic Withstand Voltage | 500 V AC (1 minute field/logic separation) |
| Operating Ambient Temp | 0 °C to +55 °C; compact racks limited to 0–40 °C |
| Storage Temperature Range | -40 °C to +70 °C, 5–95 % RH non-condensing |
| Physical Interface | DB25 Versatile Link fiber connector on TP853 base |
| Hot-Swap Rating | IEC certified for live rack replacement |
| PCB Coating Grade | ISA-S71.04 G3 anti-corrosion conformal coating |
| Total Assembly Weight | 0.70 kg (module + TP853 baseplate) |
Quality Control Process (Engineer’s Perspective)
- Incoming Verification: Match serial numbers against ABB spare part databases; inspect DB25 pins for bending and PCB edges for corrosion. Reject units with torn anti-static packaging to block counterfeit stock.
- Live Functional Test: Mount the kit in an AC800M test rack paired with an ACS880 drive simulator. Run a continuous 24-hour load cycle, log cabinet temperature every 15 minutes, and simulate fiber cable disconnection events.
- Electrical Parameter Test: Use a 500 V Megger to measure insulation resistance between DriveBus fiber circuits and CEX logic; pass threshold set at 10 MΩ minimum. Verify chassis ground continuity with a Fluke 115 multimeter.
- Firmware Verification: Extract and record base firmware revision via Control Builder M software. Photograph DB25 pin labels and TP853 mounting latches for field reference documentation.
- Final QC & Packaging: Cap the DB25 fiber port with a plastic dust shield. Seal the full kit inside a foam-lined anti-static bag, affix a dated QC Pass label before placing the assembly in factory cardboard packaging.
Replacement Pitfall Guide
❗Firmware Mismatch: CPU firmware older than v5.0.0 lacks DriveBus synchronization register mapping. Installing the kit on outdated firmware triggers persistent DRIVEBUS FAULT alarms and skews motor sync timing. Always flash matching controller firmware before rack insertion.❗DIP Switch / Jumper Misconfiguration: Factory default bus termination settings do not match field star topologies using NDBU splitters. The final drive on every fiber segment requires a 120 Ω terminator; duplicate resistors create signal reflection and random drive dropouts.❗Terminal / Cable Incompatibility: Generic plastic fiber jumpers degrade signal at 8 Mbps transfer speeds. Only use ABB Versatile Link glass fiber cables; unshielded trunk cabling introduces VFD noise that breaks closed-loop tension control.❗Power Supply Mismatch: Calculate full rack CEX bus load with a minimum 20 % power headroom. Two of the unit plus multiple CI854 modules draw enough current to overload aging rack backplanes, triggering full rack comms resets mid-production run.❗ESD Damage: Low-humidity control rooms build static charge that burns fiber transceiver chips instantly. Lay an anti-static mat under the DIN rail, wear a grounded wrist strap, and touch bare cabinet ground for three seconds before handling the PCB.Keep these in mind and you’ll cut 90% of rework time.
Compatibility Matrix & Benchmarks
Compatibility Matrix
- CI858 (bare module) → 3BSE018135R1 : Direct — kit includes matching TP853 baseplate for plug-and-play installation
- CI854BK01 → 3BSE018135R1 : Incompatible — Profibus DP hardware cannot process proprietary DriveBus fiber protocol
- CI855K01 → 3BSE018135R1 : Incompatible — MB300 Ethernet hardware lacks optical drive communication circuits
- CI853K01 → 3BSE018135R1 : Incompatible — RS485 serial ports do not support 8 Mbps fiber drive sync signals
Benchmarks
- Scan cycle: 8 ms (simulated load, 24 connected ACS880 drive points)
- Comms throughput: 8 Mbps (ABB proprietary DriveBus fiber protocol)
- Fault detection latency: < 2 ms (fiber cable break diagnostic flag to DCS HMI)
