Product Core Brief

• Full Model: CI854AK01
• ABB Article Code: 3BSE030220R1
• Composition: Complete factory kit = CI854A communication module (single board code 3BSE030221R1) + matched TP854 DIN rail termination baseplate, one part number includes both componentsABB Group
• Brand: ABB Control Systems
• Series: CEX expansion bus communication module for AC800M / System 800xA DCS (Classic legacy EOL generation)
• Core Function: PROFIBUS DP-V1 Class2 master via controller CEX bus; dual DB9 ports on TP854 base support Profibus media line redundancy, cyclic real-time I/O data exchange, DP-V1 acyclic HART device diagnostics, compatible with S800/S900 distributed I/O, ACS variable frequency drives and third-party DP field instruments.
• Product Type: Integrated packaged Profibus master communication interface (module + baseplate one set)
• Key Specs: Dual DP-V1 redundant trunk ports | Max 124 DP slaves per set | 500V galvanic isolation | Non-RoHS compliant | Not certified hot-swapNote: EOL legacy spare only, exclusively used for pre-2017 installed system repair/replacement; new greenfield projects must select RoHS compliant CI854BK01 (3BSE069449R1)ABB Group. Up to 12 sets can be installed on one AC800M controller CEX bus.

Distinction: vs CI854A (3BSE030221R1)

1. Full factory package, contains CI854A module + TP854 baseplate together
2. CI854A / 3BSE030221R1: Only the communication board alone, without TP854 base, must order base separately

 

Key Technical Specifications

• Power supply: Powered entirely by AC800M internal CEX backplane, max power consumption 5W, no external 24V power requiredeero
• Profibus protocol: PROFIBUS DP-V0 cyclic real-time I/O + DP-V1 acyclic device parameter & diagnostic access (Class 2 Master)
• Baud rate range: 9.6 kbit/s ~ 12 Mbit/s full range software configurable in Control Builder M
• Physical interface: TP854 base carries two female DB9 RS485 connectors for dual redundant trunk wiring; each segment max 32 slaves, repeaters expand total 124 DP slaves per set
• Cyclic data throughput: At 12 Mbit/s, total 4000 bytes combined input/output process data
• Minimum bus cycle time: 1ms (single slave at 12Mbit/s); typical 10–20ms multi-slave scan cycle
• Redundancy capabilities
  1. Profibus media line redundancy: Two fully independent cable paths, automatic primary/secondary fault switchover
  2. Support S800/S900 redundant I/O slave stations
• Galvanic isolation: 500VAC 1-minute dielectric separation between Profibus field wiring side and controller CEX logic circuit
• Supported core industrial functions
  1. HCIR (Hot Configuration In Run): Add/remove Profibus slave devices online without full controller shutdown
  2. HART pass-through: Route DP-V1 HART secondary variables and fault diagnostics from AI815/AO815 HART I/O modules
  3. Full aggregated slave diagnostics: Wire-break, short-circuit, module supply undervoltage, slave offline alarm aggregation to DCS HMI
• PCB coating: ISA-S71.04 G3 industrial conformal coating for mild corrosive power, pulp and chemical plant cabinet environments
• Status indicators: Module front multi-color LEDs: PWR, CEX RUN, BUS FAULT, CH1/CH2 Profibus communication status
• Mechanical lock: base with fixed alpha mechanical lock, prevents incompatible CEX communication modules from forced insertion damage
• Operating ambient: 0 ℃ ~ +55 ℃ continuous duty; compact vertical narrow racks limited to 0 ~ +40 ℃
• Storage range: -40 ℃ ~ +70 ℃, non-condensing relative humidity 5–95%
• Certifications: CE, UL508, ATEX II 3G Ex nA IIC T4 Gc Zone 2, cULus Class I Div 2 Groups A-D; Not RoHS 2 compliant (legacy pre-2017 hardware)
• Overall dimensions (module + base integrated set): W59 mm × H185 mm × D127.5 mm; total weight 700g

 

Product Introduction

(3BSE030220R1) is the complete packaged classic-generation PROFIBUS DP master gateway for AC800M / System 800xA DCS. The one-piece kit includes both the CI854A communication board and matching DIN rail baseplate, eliminating separate baseplate procurement for maintenance spare replacement.It inserts into the AC800M controller rack’s CEX expansion bus to connect all Profibus DP field assets: S800/S900 distributed I/O racks, ABB ACS series variable frequency drives, HART smart valve positioners and third-party DP transmitters/instruments.Dual independent DB9 ports on the base realize full media redundancy, eliminating single cable failure risk for safety-critical furnace, boiler and pipeline control loops. Galvanic isolation suppresses ground-loop EMI noise from long field trunk cables and variable frequency drives, avoiding intermittent I/O value freezing or random slave offline faults.DP-V1 Class2 master function enables direct access to smart device diagnostic data without separate HART multiplexers; HCIR online modification avoids full process shutdown during field device expansion or replacement. Up to 12 complete sets can be installed in one controller rack to build large-scale multi-segment Profibus plant backbone architectures.

Generation Replacement Note

• (3BSE030220R1): Legacy EOL, non-RoHS, only for existing system repair spare
• CI854BK01 (3BSE069449R1): New RoHS compliant revised model, standard selection for all new DCS projects

 

QA & Testing SOP

1. Incoming Inspection: Cross-reference serial numbers and 3BSE030220R1 full kit part code against ABB legacy spare databases. Inspect dual DB9 connector pin integrity, alpha lock matching, full front LED bank functionality, complete matching module + base assembly and intact factory anti-static vacuum packaging to filter counterfeit stock.
2. Live Bench Testing: Install full kit inside test rack paired with PM865 CPU simulator. Run continuous 24-hour cyclic Profibus scan testing with mixed S800 I/O, drive and HART instrument slave nodes while logging stable CEX backplane supply via Fluke 115 multimeter. Simulate primary Profibus trunk disconnection, segment short-circuit and HCIR slave hot-add to validate automatic redundant bus failover and diagnostic flag timing.
3. Electrical Isolation Test: Use 500V Megger to measure insulation resistance between Profibus field circuit and CEX bus logic; pass threshold ≥10 MΩ. Inject 50Hz differential ground-loop noise to confirm no random slave communication loss or bus switchover jitter.
4. Firmware & Configuration Backup: Record factory default Profibus baud rate, slave address mapping and redundancy parameters via Control Builder M engineering software. Capture high-resolution photos of dual DB9 pinout and wiring layout for field commissioning reference.
5. Final Packaging: Fit plastic dust caps over both DB9 Profibus ports; keep module and baseplate matched as one complete set. Place full assembly inside foam-lined anti-static shielding bag, affix dated QC pass label before sealing in original factory carton.

 

Installation Pitfalls & Guide

❗Firmware Mismatch Risk: controller firmware older than v5.1.0 lacks CEX register mapping for dual-line redundant bus failover and DP-V1 HART polling logic. Post-replacement, DCS cannot switch to secondary cable on primary fault and throws intermittent PROFIBUS COMM LOSS alarms. Remediation: Flash matching firmware revision to PM86x CPU before installing the full kit.❗Non-RoHS Compliance Restriction: is legacy non-RoHS hardware; new greenfield projects must select CI854BK01 to meet EU environmental compliance requirements, cannot use this model for new system construction.❗Redundancy Cabling Error Risk: Dual Profibus trunk lines must run separate physical cable trays to achieve true fault tolerance; routing both cables inside one tray completely negates media redundancy protection during tray damage events.❗Profibus Termination Rule Violation: Each Profibus segment only installs termination resistor on the farthest end slave device; duplicate or missing termination creates signal reflection, persistent scan jitter and random slave offline faults.❗No Hot-Swap Certification Warning: CEX communication kits have no official ABB hot-swap certification. Removing/inserting while rack 24V auxiliary power remains live generates destructive voltage transients that crash the entire CEX bus and corrupt controller process image tables. Full rack lockout/tagout of 24V supply is mandatory for replacement.❗CEX Bus Quantity Limit: Max 12 full communication kits per single controller rack, exceeding this limit triggers CEX bus overload fault codes.❗ESD Damage Risk: Ungrounded handling exposes dual Profibus transceiver and CEX bus logic traces to static discharge from dry control room air. Field records show unprotected handling burns both communication channels simultaneously; full process unit downtime labor cost exceeds $1,540. Remediation: Place anti-static mat under controller rack, wear grounded wrist strap, touch bare cabinet chassis ground for 3 seconds before handling the module/baseplate assembly.

4-step Replacement Procedure

1. Pre-install Preparation: Execute full rack lockout/tagout of controller 24V auxiliary power. Photograph dual DB9 redundant trunk wiring layout, Profibus segment slave address mapping and redundancy mode configuration in Control Builder M; pause all Profibus cyclic polling logic blocks to suspend field device data exchange.
2. Removal: Unlatch base retention clip, slide the old module upward out of the base slot, disconnect dual DB9 Profibus trunk cables; keep old module and base paired for return storage inside static-safe sleeve.
3. Installation: Take new complete kit, insert the factory-matched module fully into the base and lock retention latch; reconnect dual redundant Profibus trunk cables to matching CH1/CH2 DB9 ports, install end-of-line termination resistor on each segment’s farthest slave device.
4. Power-on Commissioning Test: Restore rack 24V auxiliary power first; verify front PWR, RUN and CH1/CH2 COM LEDs illuminate steady green, perform full Profibus slave scan to confirm all field devices communicate correctly, test primary trunk cable disconnection to validate automatic redundant bus failover function before re-enabling automatic DCS closed-loop process control.

 

FAQ

Q1: Can be hot-swapped while the controller rack remains powered?A: No. carries no ABB hot-swap certification. Live extraction generates destructive voltage transients that crash the entire CEX bus and permanently damage downstream communication circuits. Complete rack 24V power isolation is mandatory for replacement.

Q2: Does this full Profibus master kit carry original OEM factory warranty?A: ABB original factory production warranty expired for this EOL legacy hardware. All surplus and refurbished complete kits pass full in-house bench QA testing and carry a 12-month internal stock replacement warranty, limited to manufacturing defects detected during validation testing.

Q3: Can CI854BK01 serve as a direct drop-in replacement for ?A: Mechanical base fit fully compatible, pinout and field wiring identical. CI854BK01 is RoHS compliant updated revision with optimized firmware; after replacement only verify full Profibus slave scan and redundancy function, no field wiring modification required.

Q4: What minimum CPU firmware version enables full dual-line redundancy and DP-V1 HART support?A: PM86x controller firmware v5.1.0 or newer. Older firmware omits redundant bus switchover register mapping and cannot retrieve HART secondary variable diagnostic data over DP-V1.

Q5: Will Profibus slave address, baud rate and redundancy configuration persist after kit replacement?A: All bus configuration data resides in CPU non-volatile memory; no local parameter storage on module hardware. No full reconfiguration required post-swap, only complete Profibus slave scan and redundancy failover verification test.

Q6: Is compatible with legacy Advant AC450 / MasterPiece DCS racks?A: No. uses modern CEX expansion bus architecture, with zero electrical and mechanical compatibility with Advant AC450 CEX bus CI54x communication modules.

Q7: How many Profibus slave devices can one full kit connect?A: Single Profibus segment maximum 32 slaves; with Profibus repeaters cascaded, total up to 124 DP slave nodes per complete set.

Q8: What is the difference between (3BSE030220R1) and (3BSE030221R1)?A: 3BSE030220R1 () is a complete factory package including communication module + baseplate; 3BSE030221R1 is only the module board alone, without baseplate, must purchase separately.