ABB CI860K01 3BSE032444R1 Kit

The CI860K01 is a high-performance communication interface module designed by ABB for its industrial automation control system series AC 800M. Its complete model identification is 3BSE032444R1. The core of this module is the CI860 Communication Interface, which must be used in conjunction with the TP860 Baseplate to form a complete FOUNDATION Fieldbus High Speed Ethernet (FF HSE) access solution.

FF HSE is a high-speed fieldbus network based on standard Ethernet (IEEE 802.3) and the TCP/IP protocol stack. It is designed to provide high-speed, deterministic data communication channels for factory automation, particularly suitable for supervisory/system-level data integration and bridging devices connecting FF H1 networks. The CI860K01 is the key component for seamlessly integrating the AC 800M controller into the FF HSE network. It connects the controller's internal CEX-Bus to the external industrial Ethernet, enabling deep integration and data exchange between the control layer, the field device layer, and the system management layer.

As an important member of the AC 800M controller family's communication modules, the CI860K01 is widely used in ABB's flagship DCS system 800xA and its subsequent versions. It is fully compatible with AC 800M hardware (4.0, 4.1, 5.0, 5.1) and the corresponding control software, providing a solid foundation for users to build efficient, reliable, and open industrial communication architectures.

II. Core Product Features

The CI860K01 is designed with the high reliability, ease of use, and flexibility of industrial products, featuring the following outstanding characteristics:

1. High-Speed Ethernet Communication: Provides one standard RJ45 interface (located on the TP860 Baseplate) supporting 10 Mbit/s and 100 Mbit/s auto-negotiation communication rates, complying with the IEEE 802.3 100Base-TX standard, ensuring high-speed and stable connection to FF HSE network devices.

2. Plug-and-Play & Hot Swap: The module supports hot-swap functionality, allowing installation, replacement, or maintenance while the system remains powered and operational. This significantly improves system availability and maintenance convenience, reducing unplanned downtime.

3. Redundancy Configuration Support: To meet the demands of high-availability applications, the CI860K01 supports FF HSE network redundancy configuration. The module front panel features dedicated PRIM (Primary) and DUAL (Backup) yellow status LEDs, clearly indicating the module's role in a redundant system.

4. Integrated Power Supply & Easy Installation: The CI860 module receives +24V DC power via the controller's CEX-Bus, eliminating the need for an additional external power supply and simplifying system wiring. The entire unit uses standard DIN rail mounting, consistent with the installation specifications of other AC 800M series modules, enabling quick project implementation.

5. Anti-Mismatch Lock Design: The TP860 Baseplate incorporates a precise two-letter code mechanical lock. This design physically prevents incompatible or incorrect types of expansion units from being installed on the baseplate, fundamentally avoiding system failures caused by incorrect hardware installation and enhancing system safety.

6. Comprehensive Status Indication: The module front panel is equipped with multiple high-visibility LEDs, including Run (Green), Fault (Red), 100Mbit/s (Speed Indicator), RxTx (Data Transmit/Receive, Yellow), and redundancy status lights. These indicators provide field engineers with intuitive and rapid information on module operation status, network connection status, and fault diagnosis.

III. System Architecture & Operating Principle

The CI860K01 solution operates through the collaboration of two physical components:

• CI860: The Communication Interface Unit, containing CEX-Bus interface logic, a communication processor, and DC/DC power conversion circuitry.

• TP860: The Mounting Baseplate, providing mechanical fixing, electrical connection ports (RJ45), and the anti-mismatch code lock.

Operating Principle:
Once the CI860 is inserted into the TP860 Baseplate, it connects via a backplane connector to the CEX-Bus expansion bus of an AC 800M controller (e.g., PM85x/PM86x). The CEX-Bus not only supplies operating power (+24V DC) to the CI860 but also serves as the high-speed channel for data exchange with the controller CPU. The control software within the controller (e.g., Control Software for AC 800M) is responsible for configuring, driving, and managing the CI860.

On the network side, users connect the RJ45 port on the TP860 Baseplate to an FF HSE network switch or other network device using standard shielded twisted-pair Ethernet cable (CAT5e or higher). The CI860 module implements the standard TCP/IP protocol stack and FF HSE application layer protocol, enabling the AC 800M controller to join the network as a standard FF HSE device. It can communicate with other HSE devices on the network (such as industrial PCs, servers, gateways) and with FF H1 field device networks that are accessed via FF HSE Linking Devices (e.g., LD 800HSE).

Important Note: The CI860 itself is an HSE interface. To connect traditional FF H1 field devices, a dedicated FOUNDATION Fieldbus Linking Device is required for protocol conversion and network bridging.

IV. Installation & Configuration

The installation process is simple and standardized:

1. Mechanical Installation: Snap the TP860 unit with the CI860 module onto a standard DIN rail.

2. Network Connection: Insert one end of a prefabricated Ethernet twisted-pair cable into the RJ45 connector on the TP860 Baseplate, and connect the other end to the FF HSE network infrastructure.

3. System Integration: Add the CI860 module to the hardware configuration within the AC 800M controller's engineering configuration software (e.g., Control Builder) and download it to the controller.

4. Network Verification: Ensure that network switches, linking devices, etc., comply with FF HSE specifications and that network configurations (e.g., IP address, subnet mask) are correct.

V. Fault Finding & Maintenance

The CI860K01 features comprehensive self-diagnostic and status indication functions. The table below summarizes common fault phenomena and troubleshooting steps, greatly facilitating on-site maintenance:

VI. Application Scenarios & Value

The CI860K01 FF HSE Interface Module is a key component in building modern, integrated industrial automation systems. It is primarily applied in the following scenarios:

• Plant-Level Data Integration: Serves as a bridge for AC 800M controllers to access plant information networks (e.g., plant monitoring network), enabling real-time upload of production data to upper-level systems like MES and ERP.

• High-Speed Process Monitoring: Connects operator stations, engineering stations, etc., providing a reliable data channel for high-speed, high-refresh-rate monitoring screens.

• FF H1 Network Integration: Integrates large numbers of traditional FF H1 fieldbus device networks into a unified HSE backbone network by connecting to linking devices like LD 800HSE, enabling a flatter network architecture and centralized management.

• System Redundancy & High Availability: In critical continuous production processes, redundant CI860K01 modules and HSE networks can be configured to provide backup communication paths, ensuring non-stop control system communication.

Its core value lies in: Enhancing System Openness (based on standard Ethernet), Improving Communication Performance (100 Mbps speed), Simplifying Network Architecture, and Increasing System Reliability & Maintainability (Hot Swap, Redundancy, Easy Diagnosis). Ultimately, it helps users reduce total lifecycle costs and improve plant operational efficiency.