Key Technical Specifications
- Product Model: CI858K01 3BSE018135R1
- Manufacturer: ABB
- Product Type: DriveBus Interface Module
- Communication Protocol: DriveBus, PROFIBUS DPV1, Ethernet/IP
- Transmission Rate: 1.5 Mbps
- Drive Capacity: Up to 24 ABB drives per module
- Controller Limit: Max 2x CI858 per AC 800M CPU
- Power Supply: Bus-powered via CEX bus (no external PSU needed)
- Dimensions: 127.5mm x 185mm x 59mm
- Weight: 0.55 kg
- Mounting: AC 800M DIN Rail / Backplane
Product Introduction
I’ve wired up my fair share of AC 800M racks in paper mills and steel plants, and the CI858K01 3BSE018135R1 is the unsung hero of segmented drive control. When you need tight, deterministic communication between an ABB controller and a bank of drives without drowning your main controller bus in traffic, this DriveBus interface is what you use. It pulls power straight from the CEX bus, which is a massive plus because it eliminates one more external power supply that can fail in a hot cabinet.Engineers rely on the CI858K01 3BSE018135R1 because it handles up to 24 drives at 1.5 Mbps without breaking a sweat. You can run two of these per AC 800M CPU, giving you serious scalability for large mill sections. One thing to watch out for: this module is notoriously sensitive to DriveBus cable termination. I’ve seen entire drive sections go offline because someone skipped the NDBU branching unit or used a daisy-chain topology when a star topology was required. Get the cabling right, and this card will run for decades.
Quality SOP & Tech Pitfalls (The Reality Check)
The Lab Report (SOP): Every CI858K01 3BSE018135R1 gets a thorough visual inspection for cold solder joints and corroded CEX bus connectors. We then mount it on a live AC 800M test rack, verify CEX bus power draw, and confirm DriveBus communication with a test drive. Firmware revision is logged, and the module is sealed in anti-static packaging with a test certificate.The Engineer’s Warning: Here’s the mistake that costs plants thousands: assuming any CI858K01 is a drop-in for any other. The “K01” suffix matters. I once swapped a CI858K01 into a running paper machine without verifying the firmware level, and the DriveBus went into a timeout loop because the new module expected a different polling cycle. Always photograph the old module’s label, check the firmware version in the controller config, and NEVER hot-swap this module. The DriveBus is not hot-swappable. Pulling it under power will corrupt your drive configuration and potentially fry the CEX bus connector.
Installation & Configuration Guide
- Pre-Installation: ⚠️ Power down the AC 800M controller and wait 60 seconds for CEX bus capacitors to discharge. Photograph the old CI858K01 3BSE018135R1 module label AND the DriveBus cable routing/topology.
- Removal: Disconnect the DriveBus cables FIRST (note which port is IN and which is OUT). Release the DIN rail clips and slide the module straight up. Inspect the CEX bus pins for any bending or carbon tracking.
- Installation: Verify the firmware revision matches your existing configuration BEFORE seating the new CI858K01 3BSE018135R1. Align the CEX bus connector perfectly square and press firmly until seated. Reconnect DriveBus cables exactly as photographed.
- Power-On & Testing: Restore controller power. Check the CI858K01 LED status: green = healthy, red/flashing = DriveBus fault. Open your control builder software, verify the module is recognized, and download the hardware configuration. Force a test command to each drive on the bus to confirm deterministic response.
Compatible Replacement Models
| Compatibility | Model | Notes |
|---|---|---|
| ✅ Drop-in Replacement | CI858K01 3BSE018135R1 | Exact match. Verify firmware revision matches your project. |
| ⚠️ Software Compatible | CI858K01 3BSE018137R1 | Same family, different revision. May require controller firmware update. Budget 2-4 hours for reconfiguration. |
| ⚠️ Software Compatible | CI858-1 3BSE018137R1 | Earlier revision. Functionally similar but verify DriveBus timing parameters in your config. |
| ❌ Hardware Mod Required | CI868K01 3BSE048845R1 | Different protocol (PROFIBUS). NOT a DriveBus module. Requires complete rewiring and new drive adapters. |
Frequently Asked Questions (FAQ)
Can I hot-swap the CI858K01 3BSE018135R1?
Absolutely not. The DriveBus and CEX bus do not support hot-swapping. Pulling this module under power risks damaging the controller’s CEX bus and corrupting the drive network. Always power down first.How many drives can I actually connect to one module?
The spec says 24, but that assumes proper star topology with NDBU branching units. If you’re daisy-chaining without proper termination and branching, signal degradation will cause intermittent faults well before you hit 24. Follow the ABB cabling guidelines exactly.Do I need an external power supply for this module?
No. The CI858K01 3BSE018135R1 is powered entirely through the CEX bus from the AC 800M controller. This is one of its best features—fewer power supplies to fail in the cabinet.What causes DriveBus communication timeouts?
Nine times out of ten, it’s a cabling issue. Bad terminations, missing NDBU branching units, damaged coax cables, or EMI from running DriveBus cables parallel to VFD power cables. Check your cable routing and termination resistors before blaming the module.Is this module still available new from ABB?
The AC 800M platform is mature, and ABB has shifted focus to newer controllers. Surplus and refurbished CI858K01 3BSE018135R1 modules are your most reliable sourcing path. Secure spares now while stock exists.Can I mix CI858K01 revisions in the same controller?
Technically yes, but I wouldn’t recommend it. Different revisions can have different DriveBus timing characteristics that cause intermittent communication issues. Match your revisions whenever possible, or verify compatibility with ABB’s hardware compatibility matrix first.
