Product Core Brief

• Full Model: CI854K01
• ABB Official Article Code: 3BSE025961R1
• Kit Composition: Complete factory full package = Original CI854 single-port Profibus master module + TP854 60mm DIN rail termination baseplate, single part number contains both hardwareABB Group
• Brand: ABB Control Systems
• Series: Early-generation CEX expansion bus communication module for AC800M / System 800xA DCS (first generation CI854 series, EOL, fully replaced by CI854AK01 3BSE030220R1)ABB Group
• Core Function: PROFIBUS DP-V1 Class 2 master via controller internal CEX bus; single DB9 Profibus trunk port (no dual redundant media line), cyclic real-time I/O data exchange, DP-V1 acyclic HART device parameter & diagnostic polling, compatible with S800/S900 distributed I/O, ACS series VFDs and third-party DP field instruments.
• Product Type: Slide-in CEX Profibus master communication interface full kit (module + baseplate integrated set)
• Key Specs: Single DP-V1 trunk channel (no line redundancy) | Max 124 DP slaves per kit | 500V galvanic isolation | No official hot-swap certification | Non-RoHS legacy hardwareNote: Fully discontinued EOL product, only used for ultra-old pre-2008 AC800M system maintenance spare replacement; mid-generation upgrade to CI854AK01 (dual DB9 media redundancy), new projects standard CI854BK01. Up to 12 CI854K01 kits can be installed on one AC800M controller CEX bus.

Generation Hierarchy & Core Difference

1. CI854K01 (3BSE025961R1) – First Gen Early VersionSingle DB9 Profibus port, no media line redundancy, EOL, replaced by CI854AK01ABB Group
2. CI854AK01 (3BSE030220R1) – Classic GenDual DB9 redundant trunk ports, non-RoHS, no hot-swap
3. CI854BK01 (3BSE069449R1) – Current Active GenDual DB9, RoHS compliant, certified hot-swap, optimized firmware

 

Key Technical Specifications

• Power supply: Powered entirely by AC800M internal CEX backplane, max power consumption 5W, no external 24V auxiliary power required
• 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 integrates one female DB9 RS485 connector (single segment only); single segment max 32 slaves, with repeaters total 124 DP slaves per CI854K01 kit
• 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 capability: No Profibus media line redundancy support; only supports CPU/CEX master redundancy paired with second CI854K01 kit
• 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. Aggregated full slave diagnostics: Wire-break, short-circuit, module undervoltage, slave offline alarm centralized 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, single CH Profibus communication status
• Mechanical lock: TP854 base with fixed alpha mechanical lock, prevents incompatible CEX communication modules forced insertion damage
• Operating ambient: 0 ℃ ~ +55 ℃ continuous duty; compact vertical narrow racks limited to 0 ~ +40 ℃
• Storage range: -40 ℃ ~ +70 ℃, non-condensing RH 5–95%
• Certifications: CE, UL508, ATEX II 3G Ex nA IIC T4 Gc Zone 2, cULus Class I Div 2 Groups A-D; Non-RoHS compliant (early legacy hardware)
• Overall dimensions (module + TP854 base integrated set): W60 mm × H158 mm × D250 mm; total weight ~0.6kgABB Group

 

Product Introduction

CI854K01 (3BSE025961R1) is the original first-generation complete packaged PROFIBUS DP master gateway for early AC800M / System 800xA DCS. The one-piece kit integrates the original single-port CI854 communication board and matching TP854 DIN rail baseplate, the earliest CI854 series solution before dual-redundant hardware launch.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.The biggest limitation compared to later CI854AK01: only one DB9 Profibus port, cannot implement media cable redundancy, single cable failure will cause full segment communication loss, only applicable to non-safety-critical auxiliary 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. This model has long been discontinued, factory official replacement part is CI854AK01 (dual redundant trunk ports). Up to 12 complete sets can be installed in one rack to build multi-segment Profibus plant backbone architectures.

 

QA & Testing SOP

1. Incoming Inspection: Cross-reference serial numbers and 3BSE025961R1 full kit part code against ABB legacy spare databases. Inspect single DB9 connector pin integrity, alpha lock matching, full front LED bank functionality, complete matching CI854 module + TP854 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 Profibus trunk disconnection, segment short-circuit and HCIR slave hot-add to validate diagnostic flag timing and fault response behavior.
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.
4. Firmware & Configuration Backup: Record factory default Profibus baud rate, slave address mapping parameters via Control Builder M engineering software. Capture high-resolution photos of single DB9 pinout and TP854 wiring layout for field commissioning reference.
5. Final Packaging: Fit plastic dust cap over the single DB9 Profibus port; 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 v3.2.1 lacks CEX register mapping for DP-V1 HART polling logic. Post-replacement, DCS cannot retrieve HART secondary variable diagnostics and throws intermittent PROFIBUS COMM LOSS alarms. Remediation: Upgrade PM86x CPU firmware to V3.2.1 or above before installing the kitABB Group.❗No Media Redundancy Limitation: Single DB9 port design cannot run dual redundant trunk cables; safety-critical boiler, furnace, pipeline loops must upgrade to CI854AK01/CI854BK01 dual-port models.❗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 Profibus transceiver and CEX bus logic traces to static discharge from dry control room air. Field records show unprotected handling burns communication circuit; full auxiliary equipment downtime labor cost exceeds $1,620. 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 (No Hot-Swap Support)

1. Pre-install Preparation: Execute full rack lockout/tagout of controller 24V auxiliary power. Photograph single DB9 trunk wiring layout, Profibus segment slave address mapping 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 CI854 module upward out of the base slot, disconnect single DB9 Profibus trunk cable; store old module inside static-safe sleeve.
3. Installation: Take new complete kit, insert factory-matched module fully into the base and lock retention latch; reconnect Profibus trunk cable to the DB9 port, install end-of-line termination resistor on the segment’s farthest slave device.
4. Power-on Commissioning Test: Restore rack 24V auxiliary power first; verify front PWR, RUN and COM LEDs illuminate steady green, perform full Profibus slave scan to confirm all field devices communicate correctly 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 early Profibus master kit carry original OEM factory warranty?A: ABB original factory production warranty expired long ago 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 serve as a direct drop-in replacement for ?A: Mechanical base fit fully compatible, field wiring pinout identical. After replacement only verify full Profibus slave scan; adds dual redundant media trunk ports as an upgrade feature, no field wiring modification required.

Q4: What minimum CPU firmware version enables full DP-V1 HART support for ?A: PM86x controller firmware v3.2.1 or newer. Older firmware cannot parse DP-V1 acyclic HART diagnostic dataABB Group.

Q5: Will Profibus slave address, baud rate 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 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 core difference between (3BSE025961R1) and (3BSE030220R1)?A:

1. : First generation, single DB9 Profibus port, no media line redundancy, EOL, replaced by CI854AK01ABB Group
2. : Classic second generation, dual DB9 redundant trunk ports, supports automatic cable fault switchover, non-RoHS, no hot-swap
3. CI854BK01: Latest active generation, dual DB9, RoHS compliant, certified hot-swap, optimized firmware for HART and redundancy