Product Core Brief
- Model: CI867K01 (3BSE043660R1)
- Brand: ABB
- Series: CEX Expansion Bus for AC800M / System 800xA DCS
- Core Function: Enables bidirectional Modbus TCP master/slave Ethernet communication via the controller’s internal CEX backplane.
- Product Type: Full communication kit (CI867 Modbus TCP module + TP867 DIN rail termination base)
- Key Specs: Dual RJ45 Ethernet ports | 10/100 Mbps auto-negotiate | IEC hot-swap certified | Condition: New Original (New Surplus)
Product Introduction
ABB 3BSE043660R1 delivers dedicated Modbus TCP translation for AC800M controllers, linking the DCS to third-party PLCs, RTUs, and smart Ethernet instruments without serial converters. It draws all operating power directly from the rack’s CEX bus.This unit differs from single-port CI867A hardware by offering two isolated RJ45 ports to separate plant control and auxiliary monitoring networks. A single AC800M rack supports up to 12 of these kits to segment independent Modbus TCP subnets across large facility layouts.
Key Technical Specifications
| Parameter | Value |
|---|---|
| Power Source | AC800M internal CEX bus; no separate 24 V auxiliary feed |
| Typical Operating Current | 160 mA @ 24 V backplane rail |
| Max Power Dissipation | 3.8 W |
| Ethernet Port 1 Speed | 10/100 Mbps full-duplex auto-negotiate (primary Modbus trunk) |
| Ethernet Port 2 Speed | Fixed 10 Mbps half-duplex (secondary isolated subnet) |
| Modbus Mode Support | Simultaneous master and slave operation on separate ports |
| Max Per AC800M Rack | 12 units (single or paired module redundancy) |
| Galvanic Isolation Rating | 2500 V RMS 1 minute between Ethernet and CEX logic circuits |
| Operating Ambient Temp | +5 °C to +55 °C; compact vertical racks limited to 0–40 °C |
| Storage Temperature Range | -40 °C to +70 °C, 5–95 % RH non-condensing |
| PCB Corrosion Coating | ISA-S71.04 G3 industrial anti-corrosion conformal coating |
| Enclosure Protection Class | IP20 per IEC 60529 DIN rail mount |
| Full Kit Weight (Module + TP867 Base) | 0.70 kg |
| Compliance Certifications | CE, UL508, RoHS 2, WEEE, ATEX II 3G Zone 2 |
Quality Control Process (Engineer’s Perspective)
- Incoming Verification: Cross-reference serial numbers against ABB global spare part databases; inspect dual RJ45 pin integrity and TP867 base mechanical locking latches. Discard units with cracked PCB edges or torn anti-static packaging to filter counterfeit inventory.
- Live Functional Test: Mount the full kit on an test rack with PM865 CPU and Modbus TCP simulator. Run continuous 24-hour cyclic register read/write testing, log cabinet temperature every 15 minutes, and simulate Ethernet trunk cable disconnection to validate fault flag latency.
- Electrical Parameter Test: Use a 500 V Megger to measure insulation resistance between Ethernet field circuits and CEX logic; pass threshold set at 10 MΩ minimum. Confirm chassis ground continuity with a Fluke 115 handheld multimeter.
- Firmware Verification: Read and record factory firmware revision through Control Builder M software. Capture photos of dual RJ45 pin labeling and TP867 DIN rail mounting points for field commission reference.
- Final QC & Packaging: Fit plastic dust caps over both RJ45 Ethernet ports. Seal the complete kit inside foam-lined anti-static packaging, attach a dated QC Pass label before placement in factory shipping cartons.
Replacement Pitfall Guide
❗Firmware Mismatch: CPU firmware older than v5.2.0 lacks dual-port Modbus register mapping logic. Installing the kit on outdated firmware locks out Port 2 communication and triggers persistent MODBUS TCP LINK FAULT alarms. Flash matching controller firmware before rack insertion.❗DIP Switch / Jumper Misconfiguration: Factory default Ethernet auto-negotiate settings conflict with fixed-speed industrial switches. Lock Port 1 to 100 Mbps full-duplex; auto-sensing timing delays break critical closed-loop Modbus register polling.❗Terminal / Cable Incompatibility: Unshielded CAT5 cabling picks up EMI near high-power VFD stacks. Only use shielded CAT5e trunk wiring with single-point cabinet grounding at the TP867 baseplate.❗Power Supply Mismatch: Calculate total CEX bus load with a minimum 20 % power headroom. Eight of the unit plus CI854 Profibus modules overload aging rack backplanes, triggering full CEX bus resets mid-production batch runs.❗ESD Damage: Low-humidity power plant control rooms build static charge that destroys Ethernet PHY transceiver chips instantly. Lay an anti-static mat under the DIN rail, wear a grounded wrist strap, and touch bare cabinet chassis 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
- CI867 (bare module) → 3BSE043660R1 : Direct — factory kit includes matching termination base for plug-and-play rack installation
- CI867A → 3BSE043660R1 : Needs Adaptation — single-port design; software reconfiguration required to disable unused secondary subnet logic
- CI860K01 → 3BSE043660R1 : Incompatible — FF HSE protocol stack cannot decode standard Modbus TCP Ethernet frames
- CI854BK01 → 3BSE043660R1 : Incompatible — Profibus DP hardware lacks Modbus TCP translation firmware
Benchmarks
- Scan cycle: 10 ms (simulated load, 256 Modbus holding register points across dual subnets)
- Comms throughput: 100 Mbps (Port1, Modbus TCP primary control network)
- Fault detection latency: < 2.5 ms (Ethernet trunk break diagnostic flag to 800xA HMI)
