The CI854AK01 is a PROFIBUS-DP/V1 fieldbus communication interface module designed by ABB specifically for its AC 800M series of programmable controllers. This module serves as a critical bridge between the AC 800M control system and lower-level PROFIBUS DP slave devices (such as remote I/O stations, drives, sensors, etc.), enabling high-speed and reliable industrial-grade data exchange and control.
The CI854AK01 includes a CI854 communication interface unit and a TP854 mounting baseplate. This model emphasizes capabilities for redundancy and hot-swap support, making it suitable for industrial automation applications with high demands on system availability, such as process industries, power generation, and mining.
2. Key Features
Full PROFIBUS DP Master Functionality: Supports Class 1 and Class 2 master services, enabling efficient management of cyclic data exchange and acyclic communication (e.g., parameterization, diagnostics).
Dual-Line Redundancy: The TP854 baseplate provides two independent DB9-type PROFIBUS interfaces (Line A and Line B), allowing connection to two separate physical buses. Communication can automatically switch to the alternate line if one fails, significantly enhancing network reliability.
Module Redundancy & Hot-Swap (CI854A only): Supports pairing with another CI854A module in a redundant configuration for primary/backup operation. In this setup, the backup module supports hot-swap operations without interrupting the control system, facilitating maintenance and upgrades.
Slave Redundancy Support: Capable of managing and working with PROFIBUS DP slave devices that support redundancy.
Flexible Transmission Rates: Communication speed is selectable across a wide range from 9.6 kbit/s to 12 Mbit/s to suit different network sizes and real-time requirements.
Easy Installation: Features standard DIN rail mounting and integrates into the AC 800M's CEX bus. The module receives power from the processor unit via the CEX bus, eliminating the need for an external power supply.
Code Lock Mechanism: The TP854 baseplate is equipped with a pre-set alphabetical code lock that prevents the installation of incompatible communication modules, ensuring hardware compatibility and system stability.
High Expandability: By using repeaters, a single PROFIBUS DP network can support up to 124 nodes (with a maximum of 32 nodes per segment).
Galvanic Isolation: Provides electrical isolation, enhancing noise immunity and protecting the control system circuitry.
3. Installation & Configuration Overview
Installation of the CI854AK01 typically follows these steps:
Mechanical Mounting: Secure the TP854 baseplate to a standard 35mm DIN rail. Align the CI854 module with the baseplate and press down, ensuring the code lock engages.
Bus Connection:
Prepare the PROFIBUS DP cable. Using 9-pin D-Sub connectors with switchable built-in termination resistors is recommended.
Connect the cable shield to the connector's metal housing for grounding.
Connect data wire A (typically corresponding to green wire or RxD/TxD-N) to connector PIN 8.
Connect data wire B (typically corresponding to red wire or RxD/TxD-P) to connector PIN 3.
Plug the prepared cable connector into the PROFIBUS A or/and B port on the TP854 baseplate. For line redundancy, connect two independent cables to ports A and B.
Termination Setting: The bus termination resistors on the connectors must be set to ON at the two physical end nodes of the entire PROFIBUS DP network. Termination should be OFF for intermediate nodes.
System Configuration: Use ABB's Control Builder M (CBM) engineering tool to configure the AC 800M controller hardware, add the CI854 module, and set its PROFIBUS DP network parameters (e.g., address, baud rate, slave list). Download the configuration to the controller.
Redundancy Configuration: For module redundancy, correctly set the redundancy parameters in CBM, configure the two CI854A modules as primary and backup respectively, and connect the corresponding PROFIBUS lines.
4. Typical Application Areas
As the interface between the AC 800M controller and a wide range of PROFIBUS DP device networks, the CI854AK01 is widely used in the following ABB control system solutions:
Industrial & Process Automation: A standard communication component for the AC 800M controller within ABB's 800xA Extended Automation System or Compact Product Suite.
Connecting Remote I/O: Direct connection to ABB S800, S900 series remote I/O stations.
Integrating Third-Party Devices: Connecting PROFIBUS DP-compatible drives, motor starters, sensors, valve positioners, and other field devices.
Connecting Process Instruments: Connecting PROFIBUS PA instruments via a PROFIBUS linking device (e.g., LD 800P).
Industry-Specific Solutions: For example, in control systems for Gearless Mill Drives (GMD) in mining, or in thickness gauging systems within measurement & analytics applications.
5. Maintenance & Troubleshooting
The module provides clear LED indicators for status monitoring and preliminary fault diagnosis:
No LEDs lit upon power-up: Check CEX bus power and controller configuration, or attempt to initiate a reset (INIT) signal from the processor unit.
F(ault) Red LED steady ON: Indicates the module has detected an error. Check configuration in CBM, attempt a reset. If the condition persists, consider replacing the module.
RxA or RxB Yellow LED OFF: Indicates no communication on the corresponding PROFIBUS line. Check slave configuration, connections, cables, and termination settings on that line. If slave redundancy is used, verify its functionality.
DUAL LED OFF (in redundant config): Verify that redundancy for this module is correctly configured and downloaded in CBM.
Hot-Swap Procedure: Applicable only to the backup CI854 module in a redundant configuration. Ensure operations are performed only on the module designated as backup while the system is running, following the correct insertion/removal procedure.
