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ABB CI857K01 3BSE018144R1 INSUM Ethernet interface

1. Product Description

The ABB CI857K01 3BSE018144R1 is a dedicated INSUM Ethernet interface module designed for industrial automation systems, serving as a high-reliability communication bridge between ABB’s AC 800M DCS (Distributed Control System) and INSUM-compatible industrial devices. INSUM (Industrial Summation Network) is ABB’s specialized protocol optimized for real-time data aggregation and distributed control, making this module ideal for scenarios requiring synchronized data exchange across multiple field devices. The module features a 10/100 Mbps Ethernet port (RJ45) and supports bidirectional transmission of control signals, process variables, and diagnostic data. With industrial-grade EMI (Electromagnetic Interference) immunity, wide temperature adaptability, and seamless integration with the AC 800M backplane, it provides a stable, efficient solution for building INSUM-based industrial networks in harsh environments such as power plants, metallurgical facilities, and petrochemical sites.

2. Detailed Parameters

Parameter Category	Specifications
Model Number	CI857K01 (Order Code: 3BSE018144R1)
Interface Type	1 × 10/100 Mbps Ethernet port (RJ45), compliant with ABB INSUM protocol
Supported Protocols	ABB INSUM, TCP/IP, UDP; Optional Modbus TCP/IP (via firmware configuration)
Data Transfer Rate	10 Mbps (half/full duplex) or 100 Mbps (half/full duplex, auto-negotiation)
Network Topology	Star, Bus (with INSUM-compatible devices); Supports INSUM network redundancy
Communication Distance	Up to 100 meters (CAT5e/CAT6 Ethernet cable, IEEE 802.3 standard)
Power Supply	Derived from AC 800M backplane (24 V DC); Typical power consumption: 4 W
Operating Temperature	-40°C to +70°C
Dimensions (W×H×D)	48.3 × 100 × 150 mm
Mounting Method	DIN rail mounting (compatible with standard 35 mm DIN rails)
Redundancy Support	INSUM network redundancy (automatic failover to backup links, ≤50 ms switchover time)
Certification	CE, UL, IEC 61000-6-2 (EMC immunity), IEEE 802.3 (Ethernet standard)

3. Advantages & Features

INSUM Protocol Optimization: Tailored for ABB’s INSUM protocol, the module enables low-latency (≤20 ms) and synchronized data transmission, critical for distributed control scenarios requiring unified timing (e.g., multi-device coordination in power grids).

Industrial-Grade Reliability: Withstands -40°C to +70°C wide temperature range, resists EMI (IEC 61000-4-3/6) and voltage surges (IEC 61000-4-5), ensuring stable operation in harsh industrial environments with electrical noise or extreme temperatures.

Simplified Integration: Seamlessly connects to the AC 800M DCS backplane (no external power cables needed) and is configurable via ABB’s Control Builder software, reducing deployment time and integration complexity.

INSUM Redundancy Support: Supports INSUM network redundancy with fast failover (≤50 ms), ensuring uninterrupted communication even if the primary network link fails—essential for critical processes (e.g., power generation, chemical reactions) where downtime is unacceptable.

Flexible Protocol Expansion: Optional Modbus TCP/IP support (via firmware update) allows integration with third-party Modbus-enabled devices (e.g., HMIs, data loggers), expanding compatibility beyond the ABB ecosystem.

4. Application Fields

Power Generation (Thermal/Nuclear): Connecting AC 800M DCS to INSUM-compatible turbine control units, boiler feedwater systems, and generator excitation devices, enabling synchronized control of power plant subsystems for stable grid output.

Metallurgical Industry (Steel/Aluminum): Linking blast furnace temperature controllers, rolling mill speed regulators, and material handling systems to the central DCS via INSUM, ensuring coordinated operation of multi-stage metallurgical processes.

Petrochemical Refineries: Integrating INSUM-based flow meters, reactor pressure sensors, and catalytic converter controllers with the AC 800M DCS, facilitating real-time monitoring and adjustment of refining processes to meet product quality standards.

Water & Wastewater Treatment: Connecting pump stations, aeration systems, and water quality analyzers in large-scale treatment plants, using INSUM redundancy to avoid communication interruptions in critical water supply or sewage treatment processes.

5. Precautions

INSUM Network Compatibility: Ensure all connected devices (e.g., sensors, controllers) support the ABB INSUM protocol; non-INSUM devices require a protocol converter to avoid communication failures.

Cable Requirements: Use CAT5e or higher-grade shielded Ethernet cables to minimize EMI interference; limit cable length to 100 meters per link to prevent signal attenuation.

Redundancy Configuration: When setting up INSUM redundancy, ensure backup links use separate cables and network paths (e.g., different cable trays) to avoid simultaneous failure of primary and backup links.

Grounding: Connect the module’s ground terminal to the system’s protective ground (resistance ≤4 Ω) to reduce EMI and prevent static discharge damage to internal circuits.

Firmware Maintenance: Regularly check for firmware updates via ABB’s official portal; updates may include INSUM protocol enhancements, bug fixes, or new protocol support (e.g., Modbus TCP/IP), ensuring long-term compatibility and performance.

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