ABB 3BSE018137R1 CI858-1 Retrofit-Ready DriveBus for AC800M

ABB 3BSE018137R1 CI858-1 Retrofit-Ready DriveBus Module for AC800M Control Systems

The ABB 3BSE018137R1 CI858-1 is a DriveBus Communication Interface module designed for the ABB AC800M distributed control platform. As legacy AC800M installations age and original CI858-1 units reach end-of-life or become increasingly difficult to source, this module serves as a direct retrofit replacement — enabling engineers to restore full DriveBus and PROFIBUS DP master functionality without redesigning the control architecture or rewriting application logic.

Whether you are recovering from an unplanned failure, executing a planned control cabinet upgrade, or migrating from an older AC800 or Advant OCS platform, the CI858-1 provides a reliable, tested, and immediately deployable solution. SMARTNEXMSK maintains verified stock of the 3BSE018137R1 with full functional testing prior to shipment and a 12-month warranty on every unit.

Upgrade Compatibility Table

Retrofit Planning for Existing Automation Systems

Successful retrofit of the CI858-1 (3BSE018137R1) into an existing AC800M system requires careful pre-migration planning across several dimensions. Engineers should begin by auditing the current rack configuration — confirming available slot positions in the AC800M TB820V2 or TB840A backplane and verifying that the power supply module, typically an SD821 or SD822 24VDC unit, can support the additional current draw of the communication module without exceeding rail capacity.

On the I/O side, existing S800 I/O modules such as the AI810 analog input or DO810 digital output modules connected via the DriveBus segment must be enumerated and their addresses confirmed before the new CI858-1 is inserted. Address conflicts between the replacement module and existing nodes on the PROFIBUS DP network — including third-party variable frequency drives, motor starters, and remote I/O stations — must be resolved in the GSD configuration prior to going live.

For sites running ABB ACS800 or ACS880 drives on the DriveBus segment, the CI858-1 provides native protocol support, eliminating the need for external protocol converters. Where older ACS600 drives are still in service, compatibility should be verified against the drive firmware version before committing to the migration plan.

Control Builder M project files should be backed up and version-controlled before any hardware swap. The module’s hardware configuration object within the project must be updated to reflect the new CI858-1 slot assignment. If the site previously used a CI854A PROFIBUS DP module in the same slot, the hardware type must be changed in the project tree, and a full download to the PM864 or PM866 controller is required to activate the new configuration.

HMI screens built on ABB 800xA or legacy Operate IT environments typically do not require modification, as the DriveBus and PROFIBUS data objects retain their tag names and addresses. However, commissioning engineers should verify all faceplates and trend displays are reading live values after the module swap before releasing the system back to operations.

For sites using PROFIBUS PA segments connected through a DP/PA coupler, the CI858-1’s DP master port handles the segment master role without additional configuration beyond the standard GSD import. Communication cables, termination resistors, and cable shielding should be inspected during the retrofit window to prevent intermittent faults after restart.

Downtime Control During System Migration

Minimizing production downtime during a CI858-1 module replacement is achievable with disciplined pre-staging and a structured cutover sequence. The recommended approach is to pre-configure the replacement 3BSE018137R1 module offline using a spare AC800M rack or a bench test setup, loading the correct Control Builder M hardware configuration and verifying PROFIBUS slave communication before the planned maintenance window begins.

During the cutover, the existing module should be removed only after the controller has been placed in a safe hold state, with all output modules — including AO820 analog outputs and DO820 digital outputs — confirmed in their safe-state positions. The replacement CI858-1 is then inserted, the controller restarted, and a partial download executed to activate the new module configuration without overwriting the application program.

PROFIBUS DP slave diagnostics should be checked immediately after restart using the Control Builder M online diagnostic view. Any slaves reporting configuration faults should be addressed individually — typically caused by GSD version mismatches or address conflicts introduced during the migration. DriveBus segment health can be verified through the module’s built-in LED indicators and the 800xA hardware status display.

For critical processes where even a brief interruption is unacceptable, a hot-standby AC800M configuration using redundant PM866 controllers with synchronized application state allows the CI858-1 swap to be performed on the standby controller first, followed by a controlled switchover — keeping the process running throughout the entire migration sequence.

SMARTNEXMSK provides pre-shipment functional testing documentation for every 3BSE018137R1 unit, reducing on-site commissioning risk and supporting faster return-to-service after the module swap. All units ship with a 12-month warranty and are available for same-day dispatch on confirmed orders.

Retrofit Support FAQ

Q1: Is the ABB 3BSE018137R1 CI858-1 a direct drop-in replacement for the CI854A?
A: The CI858-1 and CI854A occupy the same AC800M rack slot and share the PROFIBUS DP master function, but they are different hardware types in Control Builder M. A hardware configuration update and full download to the controller is required. The application program logic does not need to be rewritten, and existing PROFIBUS GSD files and slave configurations remain valid.

Q2: What wiring changes are needed when replacing an existing DriveBus module?
A: The CI858-1 uses a standard PROFIBUS DB9 connector for the DP port and a dedicated DriveBus port for ABB drive connectivity. If replacing a CI858 (earlier revision), the wiring is identical. If migrating from a CI854A, the DriveBus port wiring must be added. Existing PROFIBUS cable termination and shielding should be inspected and confirmed during the replacement window.

Q3: How is compatibility with ABB 800xA verified before commissioning?
A: The CI858-1 is fully supported in ABB 800xA System Version 5.1 and later. The module appears as a standard hardware object in the 800xA plant explorer. After the Control Builder M download, the 800xA connectivity server automatically re-establishes communication with the module. No additional licensing or software configuration is required for standard DriveBus and PROFIBUS DP operation.

Q4: What does the 12-month warranty cover, and what testing is performed before shipment?
A: Every ABB 3BSE018137R1 CI858-1 unit supplied by SMARTNEXMSK undergoes full functional testing including DriveBus port verification, PROFIBUS DP master initialization, and backplane communication checks. The 12-month warranty covers hardware defects and functional failures under normal operating conditions. Units are shipped with test documentation. Replacement or repair is provided at no charge within the warranty period.

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