The CI857K01 is a communication interface module developed by ABB specifically for industrial automation control systems, known as the "CI857K01 INSUM Ethernet Interface." This product is a key component of the AC 800M controller series, primarily used to enable efficient and reliable data communication between the AC 800M controller and the INSUM Intelligent Motor Control System. The CI857K01 features a modular design, consisting of two parts: the Communication Interface Unit CI857 and the Baseplate TP853. It supports DIN-rail mounting and is suitable for various industrial field environments.
This interface module connects via standard Ethernet (TCP/IP protocol) and communicates with the underlying INSUM system through the LON interface of an INSUM TCP/IP Gateway, enabling integrated management of motor protection, measurement, and control functions by the controller. The CI857K01 is compact, easy to install, and supports hot-swap functionality, allowing module replacement without powering down the system, significantly enhancing maintenance convenience and system availability.
As a critical communication component within ABB's 800xA Control System and Compact Product Suite families, the CI857K01 is fully compatible with multiple versions of the AC 800M hardware platform (4.0, 4.1, 5.0, 5.1, 6.0, etc.), meeting the communication integration needs of automation projects from different eras and scales.
2. Product Composition and Package
The CI857K01 is a complete kit package containing two core components:
CI857 Communication Interface Unit: Contains the CEX-Bus logic circuit, communication processor, and DC/DC converter, responsible for protocol handling, data exchange, and power conversion.
TP853 Baseplate: Provides the physical mounting interface and electrical connection ports for the module. It includes two RJ45 Ethernet ports (only COM1 is used for INSUM communication) and integrates a mechanical keying lock to prevent the installation of incompatible units.
The package has a net weight of approximately 0.7 kg and is a plug-and-play solution, eliminating the need for users to order components separately and simplifying procurement and inventory management.
3. Key Features and Functions
1. High-Performance Ethernet Communication
Provides one 10 Mbit/s half-duplex Ethernet port (RJ45) via COM1 for connection to the INSUM TCP/IP Gateway.
Utilizes a mature TCP/IP protocol stack to ensure stable and real-time data transmission with the INSUM system.
2. Integration and Easy Installation
Integrated unit and baseplate design allows for direct mounting on standard DIN rails, saving cabinet space.
Receives +24V DC power from the processor unit via the CEX-Bus, eliminating the need for an external independent power supply and simplifying wiring.
3. High Reliability and Maintainability
Hot-Swap Support: Allows module replacement while the system is running, minimizing downtime.
Mechanical Keying Lock: A pre-installed two-letter code lock on the baseplate prevents the installation of incorrectly matched unit types, protecting system integrity.
Comprehensive Status Indication: Equipped with multi-color LED indicators that display operating status, faults, and data transmission/reception in real-time, facilitating quick diagnosis.
4. Broad System Compatibility
Fully compatible with the ABB AC 800M controller series and control systems such as 800xA and Compact Product Suite.
Supports cooperation with various versions of AC 800M hardware and system software, offering good upgrade and expansion capabilities.
5. Compliance with Environmental and Safety Standards
The product complies with the EU RoHS Directive (2011/65/EU), restricting the use of hazardous substances.
Classified under category 5 "Small Equipment" (no external dimension more than 50 cm) of the WEEE directive, meeting waste treatment standards for electrical and electronic equipment.
Protection rating IP20 (according to EN60529/IEC 529), suitable for general industrial indoor environments.
4. Installation and Connection Guide
1. Installation Steps
Rail Mounting: Securely clip the TP853 baseplate onto the standard DIN rail. Refer to the AC 800M Unit Mounting Manual if necessary.
Module Mounting: Align the CI857 communication interface unit with the guide slots on the TP853 baseplate and insert it. Ensure the keying lock engages. An audible click indicates proper installation.
Electrical Connection:
Power: No separate wiring required; power is supplied automatically via the backplane CEX-Bus.
Communication Cable: Connect one end of a shielded twisted-pair Ethernet cable to the COM1 RJ45 port on the TP853 baseplate.
Network Connection: Connect the other end of the cable to the Ethernet port of the INSUM TCP/IP Gateway. Ensure the network switch is functioning correctly.
2. Connection Notes
Use only the COM1 port for INSUM communication; the COM2 port is unused in this application.
It is recommended to use shielded Ethernet cables suitable for industrial environments with proper grounding to enhance noise immunity.
Ensure reliable physical connections throughout the communication path (Controller - CI857 - Switch - Gateway - INSUM).
5. LED Indicator Description and Fault Diagnosis
The front panel LEDs on the CI857 are the primary tools for diagnosing module status.
Table: LED Indicator Functions
| Indicator | Color | State | Meaning and Description |
| F(ault) | Red | Steady ON | A unit error is detected. Controlled by the Control Software. Cleared by the hardware during a controller reset. |
| R(un) | Green | Steady ON | The unit is operating normally and performing tasks. Controlled by the Control Software. |
| Tx1 | Yellow | Flashing | Indicates data is being transmitted from the COM1 port. The flashing rate corresponds to data traffic. |
| Rx1 | Yellow | Flashing | Indicates data is being received on the COM1 port. The flashing rate corresponds to data traffic. |
| Tx2/Rx2 | - | OFF | Not used in this application. |
Common Fault-Finding Guide:
| Fault Condition | Possible Cause and Corrective Action |
| Neither R(un) nor F(ault) LEDs are ON | 1. The module is in the process of being restarted or configured. Allow time for this to finalize.
2. If the condition persists, and no other unit LED on the CEX-Bus is lit:
- Check that a valid HW configuration including the CI857 is downloaded to the controller.
- Check the CEX-Bus fuse inside the processor unit.
- Initiate a reset signal (INIT) from the processor unit.
- Consider replacing the CI857 unit. |
| F(ault) LED is ON | 1. Check all cables and connectors for damage and loose or poor connections. Repair as necessary. |
| R(un) LED is flashing | 1. Check that the relevant units are sending data.
2. The module might be in the process of being restarted or configured. Allow time for this to finalize.
3. If the condition persists:
- Halt the application program and initiate a restart.
- Consider replacing the CI857 board. |
| Tx1 LED is ON (not flashing) | The unit is not transmitting data. Check the Control Builder for a failure message. |
| Rx1 LED is ON (not flashing) | The unit is not receiving data. Check all cables and connections. |
7. System Integration and Application
The CI857K01 acts as a bridge within the ABB automation architecture. Its typical application architecture is as follows:
AC 800M Controller → CEX-Bus → CI857K01 → Ethernet → INSUM TCP/IP Gateway → LON → Underlying INSUM Devices (e.g., Motor Protectors)
Through this connection, the AC 800M controller can:
Centrally monitor and manage distributed INSUM intelligent motor devices.
Read real-time motor parameters (e.g., current, voltage, temperature, status).
Send control commands (e.g., start, stop, reset).
Receive and process motor protection alarms and fault information, enabling predictive maintenance.
This interface is particularly suitable for applications in process industries (e.g., chemical, oil & gas, pharmaceutical), power, water treatment, and other sectors that require centralized control, protection, and energy management of motor devices.
