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The ABB CI854AK01 (3BSE030220R1) is a high-performance PROFIBUS-DP/V1 master communication interface module designed exclusively for ABB‘s AC 800M and 800xA distributed control systems (DCS). As a core component of ABB’s fieldbus communication portfolio, the CI854AK01 serves as the critical bridge between the AC 800M controller and PROFIBUS-DP field devices, enabling real-time, deterministic data exchange in demanding industrial environments. Supplied with the TP854 baseplate for seamless integration, the 3BSE030220R1 features dual isolated PROFIBUS ports, robust redundancy capabilities, and advanced diagnostics, making it ideal for mission-critical applications requiring uninterrupted connectivity with PROFIBUS-DP devices such as remote I/O, drives, sensors, and actuators. This guide provides comprehensive technical specifications, application examples, installation precautions, and maintenance procedures for the ABB CI854AK01.

Important Note: This module is not RoHS 2 compliant and is intended for repair, reuse, or upgrade of existing systems installed before July 22, 2017. For new installations, please use the successor model CI854BK01 (3BSE069449R1) .

Model Number ABB CI854AK01

Order Code 3BSE030220R1

Product Type PROFIBUS-DP/V1 Master Communication Interface Module

Product Series AC 800M / 800xA / S800 I/O

Communication Protocol PROFIBUS-DP-V0 / DP-V1 (supports cyclic + acyclic data exchange)

Transmission Rate 9.6 kbps – 12 Mbps (auto-negotiation / manual configuration)

Ports 2 x PROFIBUS DP ports (galvanically isolated, supports line redundancy)

Internal Interface ModuleBus for S800 I/O connection

Physical Layer RS-485 differential signal

Master Role PROFIBUS DP Class 1 Master

Maximum Slaves 31 PROFIBUS DP slave devices

Redundancy Support Line redundancy + Master redundancy (requires two modules)

Hot Swappable Yes (with TP854 baseplate)

Power Supply 24V DC nominal (18 – 30V DC wide range)

Power Consumption ≤ 3.5 W (typical 2.5W)

Isolation PROFIBUS side: 2500V rms / 500V AC

Operating Temperature -25°C to +70°C (or -20°C to +60°C depending on source)

Storage Temperature -40°C to +85°C

Humidity 5% – 95% RH (non-condensing)

Protection Rating IP20

Mounting DIN rail (TH35-7.5/TH35-15) via TP854 baseplate

Dimensions (H x W x D) 186 x 59 x 127.5 mm (approx.)

Weight 0.59 kg (approx.)

Certifications CE, UL, PROFIBUS Conformance Test Certificate

Status Indicators RUN, ERR, BUS, DIA LEDs

Successor Model CI854BK01 (3BSE069449R1) – RoHS compliant

Dual Isolated PROFIBUS Ports – The ABB CI854AK01 features two independent, galvanically isolated PROFIBUS DP-V1 interfaces that enable line redundancy and connection to separate fieldbus segments, significantly enhancing network resilience and fault tolerance.

PROFIBUS DP-V1 Compliance – Fully compliant with PROFIBUS DP-V0 and DP-V1 standards, the 3BSE030220R1 supports both cyclic I/O data exchange for real-time control and acyclic parameterization, configuration, and alarm handling with intelligent field devices.

High-Speed Communication – Supporting baud rates from 9.6 kbps up to 12 Mbps, the CI854AK01 provides low-latency data transfer for time-critical control applications such as motion control and high-speed packaging lines.

Redundancy Support – The ABB CI854AK01 fully supports hot-swap module redundancy. Two CI854AK01 modules can operate in a redundant pair (master/standby configuration), ensuring seamless failover and zero downtime in critical processes. When combined with CPU redundancy (e.g., BC810 module), it builds a highly reliable control system.

Comprehensive Diagnostics – Integrated LED status indicators (RUN, ERR, BUS, DIA) and advanced diagnostic functions in Control Builder M allow real-time monitoring of network health, slave status, and communication errors, dramatically simplifying commissioning and troubleshooting.

TP854 Baseplate Integration – The 3BSE030220R1 is supplied with the TP854 baseplate, which provides mechanical mounting, electrical connections, and hot-swap capability for seamless integration into the AC 800M rack.

Industrial-Grade Robustness – Engineered for harsh industrial environments, the CI854AK01 features a wide operating temperature range (-25°C to +70°C), high electrical noise immunity (2500V rms isolation), and IP20 protection, ensuring reliable operation on plant floors and outdoor cabinets.

DIN Rail Mounting with Hot-Swap – The ABB CI854AK01 installs on standard 35mm DIN rail via the TP854 baseplate and supports hot-swap functionality, enabling module replacement without powering down the I/O station or interrupting process control.

Easy Engineering Integration – Seamlessly integrates with ABB‘s Control Builder M and 800xA engineering tools for intuitive configuration, automatic device scanning, and straightforward I/O mapping.

S800 I/O Compatibility – The 3BSE030220R1 connects directly to ABB’s S800 I/O system via the ModuleBus interface, enabling expansion of up to 64 mixed signal channels for distributed I/O applications.

ABB CI854AK01 (3BSE030220R1) Primary model – PROFIBUS-DP/V1 master communication interface (this guide)

ABB CI854BK01 (3BSE069449R1) Successor model to CI854AK01; RoHS compliant; recommended for new installations

ABB CI854A (3BSE030221R1) Standard version of CI854; supports PROFIBUS DP-V1 protocol

ABB CI854B (3BSE025347R1) Variant of CI854 for specific fieldbus configurations

ABB TP854 Baseplate / mounting unit required for CI854AK01 installation; included with the module

ABB CI853K01 Single RS-232-C communication module for serial communication applications

ABB CI855K01 Dual Ethernet port module supporting Modbus TCP/IP communication

ABB CI867 Ethernet/IP communication interface module for S800 I/O

ABB CI871 PROFINET communication interface module for S800 I/O

ABB PM861 / PM863 / PM864 AC 800M CPU modules commonly paired with CI854AK01 for control logic execution

ABB BC810 CPU redundancy module; pairs with 3BSE030220R1 for high-availability systems

ABB S800 I/O Modules (AI810, AO845, DI880, DO880) Analog and digital I/O modules that connect via CI854AK01 in distributed I/O stations

ABB LD 800P PROFIBUS PA link module; extends CI854AK01 to connect PROFIBUS PA field devices

ABB CI801 Communication interface for Advant OCS; alternative for AC 800F controller integration

ABB TB805 ModuleBus connectors for daisy-chaining S800 modules with 3BSE030220R1

Pre-Installation Preparation

Verify system compatibility – Confirm that your ABB controller (AC 800M PM861/863/864) and engineering software (Control Builder M or 800xA) support the ABB CI854AK01 3BSE030220R1. For new installations, consider the successor model CI854BK01.

De-energize the I/O station – Isolate 24V DC power to the AC 800M rack or S800 I/O station before handling the CI854AK01. Lockout/tagout per facility safety procedures.

Prepare tools and materials – Gather: ESD wrist strap, small flathead screwdriver, PROFIBUS connectors (with termination resistor switches), shielded twisted-pair PROFIBUS cable (120Ω characteristic impedance), label maker, and documentation.

Back up existing configuration – Export the current PLC program and I/O configuration from Control Builder M. Photograph existing wiring and DIP switch settings if replacing a module.

TP854 Baseplate Installation

Mount the TP854 baseplate – Install the TP854 baseplate on 35mm DIN rail (TH35-7.5 or TH35-15) in the AC 800M rack. Ensure the baseplate is properly grounded.

Connect ModuleBus cabling – Connect the ModuleBus cables between the TP854 baseplate and adjacent S800 I/O modules or the AC 800M CPU rack. The CI854AK01 communicates with I/O modules via this internal bus.

Verify termination – Ensure proper termination of the ModuleBus segment according to ABB specifications for your specific rack configuration.

Module Installation

Install the CI854AK01 module – Align the ABB CI854AK01 with the guide rails on the TP854 baseplate and press firmly until the locking mechanism engages with an audible “click”.

Connect PROFIBUS cables – Attach PROFIBUS-DP connectors to the two 9-pin Sub-D ports on the 3BSE030220R1. Configure termination resistor switches:

End devices (first and last node on bus): Switch to “ON”

Middle devices: Switch to “OFF”

Critical: Entire bus must have exactly two termination resistors ON; deviation causes communication failure.

Ground cable shields – Connect the PROFIBUS cable shield to ground at exactly one end of the bus (typically at the master or at a central ground point). Grounding at both ends creates ground loops that induce noise.

Label wiring – Document and label both PROFIBUS ports (Port 1 and Port 2) for future maintenance reference, especially in redundant configurations.

Power-Up and Verification

Apply power – Energize the 24V DC supply to the AC 800M rack. The ABB CI854AK01 powers automatically via the backplane. Observe the LED indicators:

RUN (Green solid): Module operational, normal function

BUS (Green flashing/steady): PROFIBUS communication established

ERR (Red): Hardware fault or configuration error

DIA (Yellow): Diagnostic information present (non-critical)

Software Configuration (Control Builder M)

Add the module to the project – In Control Builder M, navigate to the I/O configuration tree. Right-click on the AC 800M controller or S800 I/O station and select “Add Module”. Select CI854AK01 (3BSE030220R1) from the module catalog.

Set PROFIBUS parameters – Configure the following parameters to match your network:

PROFIBUS address (default 1, range 1-125)

Baud rate (9.6 kbps – 12 Mbps, auto-negotiation recommended)

Watchdog timeout (default 100-500 ms)

Redundancy mode (enabled if using two CI854AK01 modules)

Configure GSD file – Import the CI854AK01 GSD file into your PROFIBUS master configuration tool. The GSD file defines module-specific parameters including I/O data length, diagnostic messages, and supported baud rates.

Scan for slave devices – Use the network scan function in Control Builder M to automatically discover PROFIBUS-DP slaves connected to the 3BSE030220R1. Assign each slave a unique PROFIBUS address (1-125, no duplicates).

Map I/O data – Define the input and output data exchange between the PROFIBUS master (CI854AK01) and each slave device. Typical configurations include cyclic data exchange for real-time process values.

Configure redundancy (if applicable) – For redundant configurations with two ABB CI854AK01 modules, enable master redundancy in Control Builder M. The system automatically handles failover and synchronization between the primary and standby modules.

Download configuration – Compile and download the updated configuration to the AC 800M controller. The controller will automatically initialize the CI854AK01 upon power cycle or warm restart.

Commissioning and Testing

Verify communication status – Using Control Builder M, go online with the controller and navigate to the CI854AK01 diagnostics. Confirm:

Module status = “OK” or “Running”

PROFIBUS bus state = “Data Exchange”

All configured slaves are “Ready” or “Online”

No active fault messages

Test data exchange – Force or simulate a few bytes of I/O data from a PROFIBUS slave and verify the 3BSE030220R1 receives the data correctly. Repeat in the opposite direction to confirm bidirectional communication.

Test redundancy (if configured) – For redundant CI854AK01 configurations, perform a failover test by removing the primary module while the system is running. Verify seamless transition to the standby module with no loss of communication or process interruption. Document failover time.

Monitor for 30 minutes – Observe the ABB CI854AK01 for any communication interruptions, error counters incrementing, or unexpected LED state changes. Stable operation for 30 minutes indicates successful commissioning.

Document installation – Record the CI854AK01 serial number, PROFIBUS address(es), firmware version, slave device list, installation date, and configuration parameters in your maintenance management system.

Lockout/Tagout mandatory – Always disconnect, isolate, and lockout all power sources before installing, wiring, or maintaining the ABB CI854AK01 3BSE030220R1. Verify zero voltage using a calibrated meter.

ESD protection required – The CI854AK01 contains sensitive electronic components. Always use grounded wrist straps and anti-static work surfaces when handling the module.

Use successor for new installations – The 3BSE030220R1 is not RoHS 2 compliant and is intended only for repair or upgrade of existing systems installed before July 22, 2017. For new installations, use CI854BK01 (3BSE069449R1) .

Termination resistor rule – On a PROFIBUS-DP network with ABB CI854AK01, the first and last physical devices must have termination resistors enabled (switch ON). All middle devices must have termination OFF. Violating this rule (more or fewer than two terminations) causes communication errors or complete bus failure.

Maximum cable length – For the CI854AK01, PROFIBUS cable length depends on baud rate: 100m at 12 Mbps, 200m at 1.5 Mbps, 400m at 500 kbps, 1000m at 93.75 kbps. Exceeding these lengths requires repeaters.

Use certified PROFIBUS cable – The 3BSE030220R1 requires shielded twisted-pair cable with 120Ω characteristic impedance (Type A PROFIBUS cable). Using incorrect cable types degrades signal quality and reduces maximum distance.

Ground shield at one end only – Connect the PROFIBUS cable shield to ground at exactly one end of the bus (typically at the master or at a central ground point). Grounding at both ends creates ground loops that induce noise.

TP854 baseplate required – The ABB CI854AK01 cannot be mounted directly on DIN rail; it requires the TP854 baseplate for proper electrical connection and hot-swap functionality.

Hot-swap compatibility – While the CI854AK01 supports hot-swapping on the TP854 baseplate, always verify your specific system configuration supports online replacement. For AC 800M rack installations with CPU redundancy, confirm compatibility.

Maintain proper clearance – Ensure minimum 10mm clearance above and below the 3BSE030220R1 for heat dissipation. Do not block ventilation slots or LED indicators.

Avoid high-EMI areas – Mount the ABB CI854AK01 away from high-voltage equipment, variable frequency drives (VFDs), and welding equipment. Maintain >30cm separation from VFD output cables.

Do not exceed 30V DC – The CI854AK01 power supply range is 18V – 30V DC (nominal 24V). Exceeding 30V DC may permanently damage the module.

Check firmware compatibility – Before installing a new CI854AK01, verify the firmware version is compatible with your AC 800M CPU firmware and Control Builder M version. Some older CPUs may require firmware updates.

Redundant module requirements – When using two CI854AK01 modules for master redundancy, both modules must have identical firmware versions. Mismatched firmware can cause failover failures.

Environmental limits – The 3BSE030220R1 operating temperature range is -25°C to +70°C. Do not install in areas exceeding these limits. For high-temperature environments, ensure adequate cabinet ventilation.

Daily / Per Shift Visual LED inspection – Walk through the control cabinet and verify the ABB CI854AK01 LED status: RUN (green solid) indicates normal operation; BUS (green flashing) indicates active communication; ERR (red) or DIA (yellow) requires investigation. Document any LED state changes in shift logs.

Weekly Communication status check – Using Control Builder M or 800xA diagnostics, review the 3BSE030220R1 error counters (CRC errors, framing errors, retries). Baseline acceptable:<10 errors per day. Increasing error rates indicate cable degradation, termination issues, or electromagnetic interference.

Monthly Slave device status verification – In Control Builder M, verify all PROFIBUS slaves connected to the CI854AK01 are online and communicating properly. Check for any slaves in “Stop” or “Fault” state. Investigate any offline devices promptly.

Monthly Thermal imaging (infrared scanning) – Using an IR camera, scan the ABB CI854AK01 during normal operation. Compare temperature readings against baseline. Alert if Δ > 15°C above ambient or any area exceeds 70°C. Elevated temperatures may indicate impending component failure or poor ventilation.

Monthly Power supply voltage check – With the CI854AK01 operating, measure the 24V DC supply at the TP854 base terminals. Acceptable range: 24V DC ±10% (21.6V – 26.4V). Low voltage causes erratic communication; high voltage may damage the module.

Quarterly PROFIBUS cable inspection – Visually inspect the PROFIBUS cables connected to 3BSE030220R1 for cuts, kinks, loose connectors, or corrosion. Verify termination resistor switches remain in the correct position (ON for end devices, OFF for middle devices).

Quarterly Connector torque verification – With the CI854AK01 de-energized (or with appropriate precautions for hot-swappable configurations), use a calibrated torque wrench to retighten all PROFIBUS connector and terminal screws. Loose connections are a leading cause of intermittent communication errors.

Semi-annually Cleaning – Remove dust accumulation from the ABB CI854AK01 using low-pressure compressed air (≤30 psi / 2 bar) and a soft brush. Do not use liquid cleaners or solvents. Hot-swap capability allows cleaning without powering down the I/O station.

Semi-annually Redundancy test (for redundant configurations) – Perform a failover test on the redundant CI854AK01 pair. Remove the primary module while the system is running and verify seamless transition to the standby module with no communication loss. Document failover time and restore the primary module.

Annually Comprehensive loop test – Perform an end-to-end communication test: from the PROFIBUS master (CI854AK01), through the network, to each field device. Measure round-trip latency and verify data integrity for all slaves. Document results and compare against baseline.

Annually Firmware version check – Verify the 3BSE030220R1 firmware version against the latest ABB release notes. Update firmware if required for new features, bug fixes, or security patches. Always back up system configuration before performing firmware updates.

Annually GSD file verification – Ensure the CI854AK01 GSD file in your engineering workstation matches the firmware version of the installed module. Mismatched GSD files can cause configuration errors after software updates.

Every 2-3 years Proactive replacement (critical applications) – For the ABB CI854AK01 in continuous 24/7 operations (power plants, chemical facilities), consider proactive replacement every 2-3 years to prevent unexpected failure. Rotate spare into service and have the removed module tested and refurbished to maintain inventory. Note that 3BSE030220R1 is discontinued; ensure spare availability.

As needed (condition-based) Immediate replacement triggers – Replace the ABB CI854AK01 3BSE030220R1 immediately if any of the following occur: persistent ERR LED that cannot be cleared by power cycle or configuration reload; complete loss of communication on a previously functional bus; visible physical damage (cracked housing, burned components, corrosion); failure to be detected by Control Builder M after verifying addressing and power; communication error counters increasing rapidly (>100 errors/hour) after verifying cable and termination.

Pro Tip: Establish a predictive maintenance program for critical PROFIBUS networks. Track communication error counters for each CI854AK01 in your asset management system. Set threshold alerts at 80% of maximum recommended errors (e.g., if ABB specifies<1000 errors/day as acceptable, alert at 800 errors/day) to schedule proactive investigation before network failure occurs.

Spare Parts Strategy: Maintain at least one spare ABB CI854AK01 (3BSE030220R1) on-site for critical processes. For facilities with multiple CI854AK01 modules, maintain spares at 10-20% of installed count. Important: The 3BSE030220R1 has been discontinued and replaced by CI854BK01 (3BSE069449R1) . Verify lead times for replacement modules. During annual shutdowns, rotate spares into service and have removed units tested to maintain inventory freshness.

Migration Planning: If your facility is planning a system upgrade, consider migrating from CI854AK01 to CI854BK01. While the modules are functionally similar, verify compatibility with your existing AC 800M CPU firmware and Control Builder M version before migration.

Failure Mode Documentation: When replacing a failed CI854AK01, document the failure mode (e.g., ERR LED steady, no BUS LED, intermittent communication, complete failure to power up). Track failure patterns quarterly to identify systemic issues (e.g., repeated failures in high-temperature cabinets suggests cooling improvements needed; multiple failures on same PROFIBUS segment suggests cable or termination issues). Share findings with ABB technical support if a pattern emerges.

Configuration Backup: After configuring the ABB CI854AK01 in Control Builder M, export and archive the complete I/O configuration, including the GSD file, slave device list, and PROFIBUS address mapping. This backup enables rapid replacement without re-entering configuration parameters if the module fails and must be replaced quickly.

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