Product Core Brief
- Model: CI860K01 (3BSE032444R1)
- Brand: ABB
- Series: CEX Expansion Bus for AC800M / System 800xA DCS
- Core Function: Bridges AC800M controllers to FOUNDATION Fieldbus HSE subnets via internal CEX bus power.
- Product Type: Full communication kit (CI860 FF HSE module + TP860 DIN rail termination base)
- Key Specs: 100 Mbps RJ45 Ethernet | Module-level redundancy support | Max 12 units per AC800M rack | Condition: New Original (New Surplus)
Product Introduction
ABB 3BSE032444R1 acts as a dedicated CEX bus gateway to map FF HSE process values directly into AC800M IEC 61131 control logicABB. It draws all operating power from the controller’s backplane with no separate 24 V supply required.This unit differs from Profinet or Profibus CEX modules by exclusive FF HSE protocol handling; it pairs with LD800HSE linking devices to connect up to four H1 instrument segments. A single AC800M rack accepts 12 of these kits to isolate independent HSE process zonesABB.
Key Technical Specifications
| Parameter | Value |
|---|---|
| Power Source | internal CEX bus, no external auxiliary feed |
| Typical Operating Current | 100 mA @ 24 V backplane rail |
| Max Power Dissipation | 2 W |
| Ethernet Speed | 10/100 Mbps auto-negotiate RJ45 HSE port |
| Supported FF Topology | HSE backbone + LD800HSE linking device for H1 field segments |
| Max Per Controller | 12 units (single or redundant paired) |
| Redundancy Support | 1+1 module redundancy on separate CEX slots |
| Galvanic Isolation Rating | 500 V AC 1 minute between HSE Ethernet and CEX logic |
| Operating Ambient Temp | 0 °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 conformal coating |
| Enclosure Protection Class | IP20 (DIN rail mounted) |
| Full Kit Weight (Module + TP860 Base) | 0.70 kg |
| Compliance Certifications | CE, UL508, RoHS 2, WEEE |
Quality Control Process (Engineer’s Perspective)
- Incoming Verification: Cross-reference serial numbers against ABB official spare part databases; inspect RJ45 pin integrity and TP860 base locking tabs. Discard units with cracked PCB edges or torn anti-static packaging to block counterfeit inventory.
- Live Functional Test: Mount the full kit on an test rack with PM865 CPU and LD800HSE simulator. Run continuous 24-hour HSE cyclic data exchange, log cabinet temperature every 15 minutes, and simulate HSE trunk cable disconnection to validate fault flag behavior.
- Electrical Parameter Test: Use a 500 V Megger to measure insulation resistance between HSE Ethernet 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 RJ45 pin labeling and TP860 DIN rail mounting points for field commission reference.
- Final QC & Packaging: Cap the RJ45 Ethernet port with a plastic dust shield. 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 v5.1.2 lacks FF HSE signal mapping registers. Installing the kit on outdated firmware creates missing FF process values and persistent HSE LINK FAULT alarms. Flash matching controller firmware before rack insertion.❗DIP Switch / Jumper Misconfiguration: Factory default Ethernet auto-negotiate settings rarely match hard-set 100 Mbps HSE switches in process plants. Lock the RJ45 port to 100 Mbps full-duplex; auto-sensing delays can break critical closed-loop FF control.❗Terminal / Cable Incompatibility: Unshielded CAT5 cabling generates EMI noise near VFD stacks. Only use shielded CAT5e trunk wiring with single-point cabinet grounding at the TP860 baseplate.❗Power Supply Mismatch: Calculate total CEX bus load with a minimum 20 % power headroom. Six of the unit plus CI854 Profibus modules overload aging rack backplanes, triggering full CEX bus resets mid-batch processing.❗ESD Damage: Low-humidity chemical control rooms build static charge that destroys Ethernet PHY chips instantly. Place 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
- CI860 (bare module) → 3BSE032444R1 : Direct — factory kit includes matching termination base for plug-and-play rack installation
- CI854BK01 → 3BSE032444R1 : Incompatible — Profibus DP hardware cannot decode FOUNDATION Fieldbus HSE Ethernet frames
- CI855K01 → 3BSE032444R1 : Incompatible — MB300 Ethernet protocol stack has no FF HSE signal mapping logic
- CI867A → 3BSE032444R1 : Incompatible — Modbus TCP interface lacks native FF HSE fieldbus translation functions
Benchmarks
- Scan cycle: 12 ms (simulated load, 64 FF H1 instrument points routed via LD800HSE)
- Comms throughput: 100 Mbps (FOUNDATION Fieldbus HSE Ethernet protocol)
- Fault detection latency: < 3 ms (Ethernet trunk break diagnostic flag to 800xA HMI)
