ABB CI857K01 3BSE018144R1 INSUM Ethernet Communication Interface Module

Description

ABB CI857K01 3BSE018144R1 INSUM Ethernet Communication Interface Module

Product Core Introduction

The CI857K01 (3BSE018144R1) is an ABB AC800M series communication interface module designed for INSUM power system communication, paired with TP853 baseplate. It connects the AC800M controller to INSUM low-voltage motor control units (MCUs) and INSUM TCP/IP gateways, enabling bidirectional real-time data exchange for motor protection, status monitoring, remote command and diagnostic information. The module communicates with the CPU via the CEX bus, powered directly by the controller backplane without external 24V auxiliary power. It supports hot-swap operation and is widely deployed in power plants, oil & gas, and large process industries for intelligent motor management systems under System 800xA platform.

CI857K01

Main Technical Specifications

• Part No: 3BSE018144R1
• Model: CI857K01
• Type: INSUM Ethernet Communication Interface Module
• Baseplate: TP853 (included in CI857K01 package)
• Backplane Bus: CEX Bus
• Power Supply: Powered via CEX bus (no external power required)
• Communication Port: 2 × 10 Mbps Ethernet for INSUM
• Max INSUM devices: Up to 128 MCUs per CI857 module; max 6 CI857 modules for single AC800M rack
• Protocol: ABB proprietary INSUM protocol
• Hot Swap: Supported
• Operating Temperature: -20 ℃ ~ +70 ℃
• Storage Temperature: -40 ℃ ~ +85 ℃
• Humidity: 5%~95% RH, non-condensing
• Protection Class: IP20 (cabinet mounted)
• Certifications: CE, cULus
• Weight: Approx. 0.7 kg (module + baseplate)

Recommended same-series ABB models

1. CI854BK01 (3BSE069449R1) – PROFIBUS DP-V1 communication module
2. CI853K01 (3BSE018103R1) – COMLI / Modbus RTU serial interface
3. CI856 – S100 I/O communication interface
4. CI864 – IEC 60870-5-104 communication module (same hardware platform, different firmware)
5. UFC933A101 (3BHE048062R0101) – Universal Field Controller Module
6. UFC912A101 (3BHE039426R0101) – EOI Emitter Output Interface Board

Quality Control Test SOP

1. Visual Inspection: Inspect PCB, solder joints, RJ45 ports, CEX bus connector, module label and baseplate, no scratch or corrosion.
2. Continuity Test: Verify CEX bus backplane connector and baseplate circuit continuity.
3. Power-on Test: Insert module to AC800M rack, power on controller, check module LED status.
4. Communication Function Test: Connect INSUM network, establish connection with INSUM MCU devices, verify data read/write.
5. Hot-swap Test: Pull out and reinsert module while rack powered, confirm automatic reconnection without rack crash.
6. Multi-device Load Test: Connect multiple INSUM nodes to validate stable data transmission under full load.
7. EMC Immunity Test: IEC 61000 ESD, EFT and surge immunity test.
8. Serial number registration and anti-static packaging.

New Module Installation

WARNING: ESD wristband is required when handling the module. Hot-swap is supported, but avoid operation during critical process condition.

1. Confirm the AC800M rack is running normally.
2. Align CI857K01 with TP853 baseplate, mount the assembly into the free CEX bus slot.
3. Lock the retaining screws of the baseplate.
4. Plug INSUM Ethernet cables into RJ45 ports, follow network topology diagram.
5. Open Control Builder M software, configure CI857 hardware and INSUM device parameters.
6. Download project to AC800M controller, perform network scan to detect all INSUM MCUs.
7. Verify motor status, protection alarms and remote control functions.

Note: Hot-swap is supported, but not recommended during critical plant running to avoid temporary communication interruption.

CI857K01

Application Scenarios & Features

Application Scenarios

• Power plant auxiliary motor control & protection (boiler fans, pumps)
• Oil & gas refinery motor management system
• Large chemical process plant low-voltage motor control
• Water treatment intelligent MCC (Motor Control Center)
• ABB System 800xA / automation system

Key Features

✅ INSUM dedicated Ethernet interface for intelligent low voltage motor controllers ✅ Hot-swap capability for maintenance without rack shutdown ✅ Powered by CEX bus, no separate external power supply needed ✅ Dual Ethernet ports for INSUM network connection ✅ Built-in diagnostic LED indicators for module status and network fault ✅ Seamless integration with and System800xA ✅ Supports large network, up to 128 MCUs per module

FAQ

Q1: Module red fault LED after insertion? A: Check if the module is correctly seated on TP853 baseplate. Verify hardware configuration in Control Builder M. Check CEX bus slot health.

Q2: Cannot discover INSUM motor units? A: Check Ethernet cable and port connection. Verify INSUM network topology and IP addressing. Confirm device address setting of each MCU.

Q3: Can CI857K01 replace CI864 directly? A: No, same hardware platform but different firmware and protocol function, not interchangeable without re-programming.

A: Store with ESD shielding bag, dry and temperature-controlled warehouse, avoid condensation, vibration and dust.

A: Communication to all INSUM motor devices on this network will be lost. Motor local protection still works, but remote monitoring and control from 800xA will be unavailable.