ABB 3BSE018137R1 CI858-1 Upgrade for AC800M DriveBus

Product Overview

ABB 3BSE018137R1 CI858-1 Upgrade for AC800M DriveBus: Seamless Transition from Legacy Drive Communication Systems

The ABB 3BSE018137R1 CI858-1 is a DriveBus Communication Interface Module designed for the AC800M process automation controller platform. It functions as a PROFIBUS DP Master, enabling high-speed, deterministic communication between the AC800M controller and ABB drive systems — including ACS800, ACS600, and DCS800 series drives — over the DriveBus protocol. For facilities managing aging control architectures or executing a phased modernization program, this module represents a proven, field-validated upgrade path that preserves existing wiring infrastructure, minimizes engineering rework, and dramatically reduces planned and unplanned downtime.

At TOPNLMS, we maintain verified stock of the CI858-1 module, fully tested prior to shipment, with a 12-month warranty and rapid international dispatch from our Xiamen facility. Whether you are replacing a failed unit on an active production line or pre-positioning spares for a scheduled turnaround, our procurement team can confirm availability, provide technical documentation, and coordinate delivery within your maintenance window.

Compatibility Comparison Table

Seamless Upgrade Solutions

A successful migration from a legacy drive communication architecture to the CI858-1 rarely involves a single component swap. In practice, the upgrade touches several interdependent layers of the control system, and understanding those dependencies is critical to achieving a smooth cutover with minimal production impact.

The CI858-1 slots directly into the AC800M controller rack, which typically houses a processor module such as the PM864A or PM866K01. If the existing processor is running an older firmware revision, a coordinated firmware update via Control Builder M Professional is recommended before commissioning the new communication module. This ensures that the DriveBus polling cycle and PROFIBUS DP master configuration tables are correctly interpreted by the controller.

On the drive side, the CI858-1 communicates with ABB drives equipped with the RDCO-04 DriveBus Adapter. For sites still operating ACS600 drives with older RDCO-02 or RDCO-03 adapters, upgrading the adapter board to RDCO-04 is a low-cost step that unlocks full DriveBus functionality and eliminates known communication timeout issues observed in mixed-revision installations. ACS800 and DCS800 drives with current RDCO-04 adapters are directly compatible without any hardware modification.

Where the existing installation uses CI854A PROFIBUS DP modules for non-drive field devices — such as remote I/O stations, valve positioners, or flow transmitters — those modules can remain in service alongside the CI858-1. The AC800M backplane supports mixed communication module configurations, allowing the CI858-1 to handle drive traffic exclusively while CI854A continues to manage standard PROFIBUS DP field devices. This parallel architecture eliminates the need for a full bus migration and allows phased decommissioning of legacy hardware.

For I/O expansion within the same control cabinet, S800 I/O modules — including AI810, AO810, DI810, and DO810 — connected via the CI810B or CI820V1 fieldbus communication interface remain fully compatible with the AC800M platform and are unaffected by the CI858-1 installation. Similarly, TB820V2 ModuleBus Modem units used for optical ModuleBus extensions do not require reconfiguration.

In control cabinets where power distribution is managed by SD831 or SD832 24 VDC power supply modules, no changes to the power architecture are required. The CI858-1 draws its operating power entirely from the AC800M backplane, keeping the cabinet power budget unchanged.

For sites that require a programming connection during commissioning, the TK212A USB-to-RS232 programming cable and a laptop running Control Builder M provide direct access to the AC800M processor for parameter verification and DriveBus node address assignment. This step is typically completed within 30 minutes for a single-drive replacement and within two to four hours for a multi-drive DriveBus segment reconfiguration.

Finally, where the migration involves decommissioning an older Advant Controller AC450 or Master fieldbus architecture, the CI858-1 and AC800M platform provide a documented migration path supported by ABB’s System 800xA engineering tools, enabling reuse of existing function block libraries and minimizing software redevelopment costs.

Retrofit Guidance FAQ

Q1: Can the CI858-1 replace a CI858 (earlier revision) without any program changes in Control Builder M?
Yes. The CI858-1 is a direct hardware revision of the CI858 and maintains full backward compatibility with existing Control Builder M project configurations. No function block reassignment, address remapping, or program recompilation is required. After physical installation, a controller warm restart is sufficient to bring the module online.

Q2: Is the DriveBus fiber optic cabling from the existing CI858 reusable with the CI858-1?
Yes. The CI858-1 uses the same fiber optic DriveBus connector interface as its predecessor. Existing HFBR-type fiber optic cables connecting to ACS800 or DCS800 drives can be reconnected directly without modification. Verify cable condition and connector cleanliness before reconnection to avoid intermittent communication faults.

Q3: What is the maximum number of drives that can be connected to a single CI858-1 module?
The CI858-1 supports up to 12 drives on a single DriveBus ring. For installations requiring more than 12 drive nodes, additional CI858-1 modules can be installed in separate AC800M slots, each managing an independent DriveBus segment. This architecture scales linearly and does not require changes to the PROFIBUS DP master configuration.

Q4: How does TOPNLMS verify module functionality before shipment?
Every CI858-1 unit undergoes a pre-shipment functional test that includes power-on self-test verification, communication port integrity check, and firmware version confirmation. Units are shipped with a test report and are covered by a 12-month warranty from the date of delivery. In the event of a warranty claim, TOPNLMS provides a replacement unit and coordinates return logistics to minimize your system downtime.

Warranty Assurance

TOPNLMS provides a 12-month warranty on all ABB 3BSE018137R1 CI858-1 modules from the date of delivery. This warranty covers manufacturing defects, functional failures under normal operating conditions, and firmware-related issues identified during commissioning. It does not cover damage resulting from incorrect installation, overvoltage events, or physical mishandling.

Prior to dispatch, each unit is subjected to a structured pre-shipment test protocol: power-on self-test, LED status verification, communication port continuity check, and firmware version logging. A test record is included with every shipment. Units are packaged in anti-static ESD-safe materials with foam cushioning to protect against transit damage.

For warranty claims, our after-sales team responds within one business day. Replacement units are dispatched from Xiamen stock upon claim approval, with express shipping options available for critical production environments. We maintain a dedicated spare inventory of high-demand AC800M communication modules to ensure rapid fulfillment without extended lead times.

For volume procurement, long-term supply agreements, or technical pre-sales consultation, contact our engineering team directly. We support OEM integrators, EPC contractors, and end-user maintenance departments with tailored sourcing strategies, including consignment stock arrangements for high-consumption SKUs.