ABB TP858 3BSE018138R1

Description

Product Overview

ABB TP858 3BSE018138R1 is a fieldbus communication interface module developed by ABB for the AC800M family of programmable logic controllers within the System 800xA automation platform. This module serves as a master/slave gateway for PROFIBUS DP networks, enabling seamless integration of remote I/O stations, variable frequency drives, intelligent field devices, and third-party equipment with ABB control systems. ABB TP858 3BSE018138R1 is designed for high-speed deterministic communication in industrial applications requiring real-time data exchange between controllers and distributed field devices. The module is extensively deployed in automotive manufacturing, material handling, water/wastewater treatment, and process industries worldwide.

Technical Specifications

ABB TP858 3BSE018138R1 features the following technical specifications:

• Function: PROFIBUS DP-V1 master/slave communication interface

• Physical Layer: RS-485, electrically isolated

• Transmission Rates: 9.6 kbps to 12 Mbps, auto-detecting

• Station Addressing: 0–126, DIP switch configurable

• Maximum Devices: 125 slaves per master (with repeater)

• PROFIBUS DP Features:

  • DP-V0 cyclic data exchange

  • DP-V1 acyclic parameterization and diagnostics

  • Sync/Freeze mode support

  • Slave-to-slave communication

• Process Data: 244 bytes input + 244 bytes output per slave

• Diagnostics: Extensive PROFIBUS diagnostics, slave status monitoring, bus statistics

• Indicators: Module status, network status, data exchange, bus error

• Power Consumption: 5 V DC, 350 mA from backplane

• Mounting: AC800M rack, occupies one slot

• Operating Temperature: 0°C to +55°C

• Humidity: 5% to 95% non-condensing

• Certifications: PROFIBUS International certified, CE, UL, CSA

A defining characteristic of ABB TP858 3BSE018138R1 is its tight integration with the AC800M programming environment. PROFIBUS configuration is performed directly within ABB’s Control Builder software using the integrated hardware catalog and GSD file import function—no separate network configuration tools are required. This unified engineering environment significantly reduces engineering time and eliminates interface errors common with third-party gateways.

Advantages & Features

ABB TP858 3BSE018138R1 represents ABB’s premium PROFIBUS connectivity solution for the AC800M platform. Key advantages include:

• Native 800xA Integration: Fully integrated with ABB’s Control Builder and System 800xA engineering environment

• High Performance: 12 Mbps communication with minimal CPU load through dedicated communication processor

• Comprehensive Diagnostics: Real-time bus statistics, slave status monitoring, and error logging accessible from controller application

• Hot Swap Capable: Module can be replaced without powering down the controller in redundant configurations

• Redundancy Support: Supports dual-channel PROFIBUS DP redundant configurations for high-availability applications

• Wide Device Compatibility: Certified with thousands of PROFIBUS DP devices from all major manufacturers

For system integrators and end users deploying AC800M controllers in PROFIBUS DP networks, ABB TP858 3BSE018138R1 provides the most reliable, best-supported connectivity solution available. The module’s proven compatibility with ABB drives, third-party VFDs, remote I/O, and process instrumentation eliminates integration risk.

Application Examples

Typical applications for ABB TP858 3BSE018138R1 include:

• Automotive Assembly Plants: Communication with PROFIBUS DP welding controllers, conveyor drives, and material handling systems

• Water Treatment Facilities: Interface with PROFIBUS DP pump drives, flow meters, and chemical dosing analyzers

• Food and Beverage: Integration of PROFIBUS DP filling machines, packaging equipment, and CIP systems

• Pharmaceutical Manufacturing: Connection of PROFIBUS DP process controllers, batch management systems, and cleanroom HVAC

• Material Handling: Communication with sortation systems, AS/RS cranes, and motor control centers

A major European automotive manufacturer standardized on ABB TP858 3BSE018138R1 for PROFIBUS DP connectivity across their global body shop construction projects. Over 500 AC800M controllers equipped with TP858 modules control thousands of welding guns, servo drives, and conveyor systems. The manufacturer reported that the module’s integrated diagnostics reduced network troubleshooting time by 70% compared to their previous PLC platform, contributing to industry-leading overall equipment effectiveness (OEE) metrics.

Competitive Comparison

Primary competitors to ABB TP858 3BSE018138R1 include Siemens CP 443-5 Extended, Emerson PROFIBUS DP master module, and third-party PROFIBUS gateways. Comparative analysis:

ABB TP858 3BSE018138R1 maintains an absolute advantage for ABB AC800M systems. Siemens and Emerson solutions are incompatible with the AC800M platform architecture. Third-party gateways require custom function block libraries, separate configuration tools, and often exhibit data consistency issues in high-speed applications. For new AC800M installations requiring PROFIBUS DP connectivity, TP858 is the only recommended solution.

Selection Recommendations & Precautions

1. Model Verification: ABB TP858 3BSE018138R1 is the PROFIBUS DP master/slave module for AC800M. Do not confuse with TP857 (PROFIBUS FMS) or TP856 (Modbus), which are mechanically similar but functionally different.

2. Firmware Compatibility: Verify that ABB TP858 3BSE018138R1 firmware version is compatible with your Control Builder software version. Firmware upgrade is possible via Control Builder over the backplane.

3. Baud Rate Considerations: While the module supports 12 Mbps, maximum network segment length at this speed is 100 meters. Use repeaters for longer distances or reduce baud rate per PROFIBUS installation guidelines.

4. Termination Requirements: PROFIBUS DP requires termination at both ends of the network segment. ABB TP858 3BSE018138R1 does not include internal termination—external termination must be provided via bus connector or termination resistor.

5. GSD File Management: Each slave device requires an electronic device datasheet (GSD file). Import these files into Control Builder before configuring the TP858 module.

6. Spare Parts Strategy: For critical applications, maintain one spare ABB TP858 3BSE018138R1 per 10 installed units or per facility, whichever is greater. Standard lead time is 4–6 weeks.

When sourcing ABB TP858 3BSE018138R1, procurement through ABB’s authorized distribution channels is strongly recommended. The module remains in active production with full factory support. Units from surplus brokers may be older revisions with limited diagnostics, may lack current firmware, or may have undocumented repair history. For safety-related applications, only new, factory-sealed modules with complete traceability documentation should be accepted. ABB offers a trade-in program allowing credit for older TP858 revisions toward purchase of current production modules—a cost-effective strategy for fleet standardization.

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