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

Overview

ABB 3BSE018137R1 CI858-1 Migration-Ready DriveBus for AC800M: Legacy System Retrofit & Upgrade

The ABB 3BSE018137R1 CI858-1 is a DriveBus Communication Interface Module designed for the ABB AC800M controller platform. As legacy automation systems approach end-of-life and original spare parts become increasingly scarce, the CI858-1 remains a critical component for engineers managing retrofit projects, control cabinet upgrades, and drive communication migrations in process industries, power generation, and manufacturing facilities worldwide.

This module provides a dedicated DriveBus interface that enables the AC800M controller to communicate directly with ABB ACS/ACS800-series drives and other DriveBus-compatible field devices. For facilities still operating on legacy ABB Advant or earlier AC800M configurations, the CI858-1 offers a validated, drop-in replacement path that preserves existing drive communication topology without requiring a full controller overhaul.

Each unit supplied by KNMKS is sourced from verified channels, subjected to pre-shipment functional testing, and backed by a support terms confirmed by quotation — giving maintenance engineers and procurement teams the confidence to plan long-term spare parts inventory for 12 to 36-month operational horizons.

Migration Compatibility Table

Retrofit Planning for Existing Automation Systems

Successful integration of the CI858-1 into a running automation environment requires careful pre-retrofit planning across several interdependent system layers. Before removing the legacy module, engineers should document the existing DriveBus node addresses assigned to each connected ACS800 or ACS600 drive, as well as the corresponding drive parameter sets stored in the AC800M application. Failure to capture this data risks extended commissioning time and unplanned production downtime.

On the controller side, the AC800M PM864 or PM866 processor module must have sufficient backplane power headroom to support the CI858-1 alongside other installed modules such as the S800 I/O modules (e.g., AI810, AO810, DI810, DO810) and any additional communication interfaces like the CI854 PROFIBUS DP master or CI857 Industrial Ethernet module. A full rack power audit using the AC800M hardware configuration tool in ABB Control Builder M is recommended before finalizing the retrofit bill of materials.

Wiring adaptation is another key consideration. The CI858-1 uses a standard D-sub 9-pin DriveBus connector. If the existing installation uses older cable assemblies with non-standard pinouts or missing termination resistors, these must be corrected before commissioning. For multi-drive topologies, the DriveBus segment termination at the last drive in the chain must be verified — incorrect termination is a common source of intermittent communication faults that are difficult to diagnose after installation.

For facilities also upgrading their HMI layer — for example, migrating from an older ABB Panel 800 or third-party SCADA to a modern system — the CI858-1 retrofit is an ideal checkpoint to audit and update all drive-related HMI tags, alarm setpoints, and trend historian links. This prevents orphaned tags and ensures the new communication path is fully reflected in the operator interface before handover.

In parallel, if the control cabinet also houses an ABB NPBA-12 PROFIBUS adapter or an RDCO DriveBus option board on the drive side, these components should be inspected and their firmware versions confirmed compatible with the CI858-1 interface. Mismatched firmware between the controller module and the drive-side adapter is a known source of communication initialization failures during first power-up after retrofit.

Downtime Control During System Migration

Minimizing production downtime during a CI858-1 replacement is achievable with structured pre-work. The most effective approach is to perform a full AC800M application backup — including all function block diagrams, SFC sequences, and drive parameter datasets — using ABB Control Builder M before any hardware is disturbed. This backup serves as both a recovery baseline and a commissioning reference.

Where process conditions allow, a hot-standby or redundant controller configuration should be leveraged to maintain field control continuity during the module swap. In non-redundant systems, coordinating the replacement during a scheduled maintenance window and pre-staging the replacement CI858-1 with the correct node address and DriveBus configuration reduces the physical swap time to under 30 minutes in most installations.

After module insertion, the AC800M will perform an automatic hardware scan. Engineers should monitor the Control Builder M hardware tree to confirm the CI858-1 is recognized at the correct slot address before downloading the application. Drive communication should be verified by checking the DriveBus status indicators on the module front panel and confirming drive status words are updating correctly in the AC800M application.

For sites with strict change management requirements, KNMKS can provide pre-shipment test reports documenting the functional verification performed on each CI858-1 unit. This documentation supports FAT (Factory Acceptance Test) and SAT (Site Acceptance Test) records and reduces the risk of field rejection due to undetected module faults.

Retrofit Support FAQ

Q1: Is the 3BSE018137R1 CI858-1 a direct drop-in replacement for the earlier CI858 module?
Yes. The CI858-1 (3BSE018137R1) is the current revision of the CI858 DriveBus interface and is mechanically and electrically compatible with the same AC800M backplane slot. No hardware modification is required. Verify that your AC800M firmware version is 5.0 or above to ensure full feature compatibility.

Q2: What pre-commissioning checks are required for wiring and termination?
Confirm that the DriveBus cable uses the correct D-sub 9-pin pinout and that termination resistors are installed at both ends of the DriveBus segment. Check cable shielding continuity and ensure the shield is grounded at one end only to avoid ground loops. For multi-drive chains, verify that only the last drive in the segment has termination enabled.

Q3: Does KNMKS provide pre-shipment testing and documentation?
Yes. Every CI858-1 unit is functionally tested before dispatch. Pre-shipment test reports are available on request and can be used to support FAT/SAT documentation. All units are covered by a support terms confirmed by quotation from the date of shipment.

Q4: What is the typical lead time and inventory availability?
KNMKS maintains stock of the ABB 3BSE018137R1 CI858-1 to support urgent retrofit and breakdown replacement requirements. Standard orders ship within 2–5 business days. For long-term spare parts agreements covering 12–36 months of supply, contact our sales team to discuss volume pricing and reserved inventory arrangements.

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Product Identification

Brand / Ecosystem

ABB
ABB

Model / Series

3BSE018137R1 CI858-1
AC800M Series

Product Family

Variable Frequency Drives

Availability Status

Available on request after model and quantity confirmation

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B2B RFQ, replacement inquiry and project spare-part request

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Specification & Inquiry Focus

Drive range

AC drives, VFDs and accessories

Common needs

Voltage, kW/HP and load type

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Motor control, energy saving and spares

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• Input/output voltage and kW/HP confirmation
• Energy-saving motor control inquiry
• Accessory and spare-unit support

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• Brand and exact model number: ABB 3BSE018137R1 CI858-1
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