3BSE020926CIOS800Profibus 399212361

IndustrialIT
800xA - Control and I/O

S800 I/O
Version 4.0
Fieldbus Communication Interface

PROFIBUS-DP/DPV1
IndustrialIT
800xA - Control and I/O
S800 I/O
Version 4.0
Fieldbus Communication Interface

PROFIBUS-DP/DPV1
NOTICE
The information in this document is subject to change without notice and should not be
construed as a commitment by ABB. ABB assumes no responsibility for any errors that
may appear in this document.
In no event shall ABB be liable for direct, indirect, special, incidental or consequential
damages of any nature or kind arising from the use of this document, nor shall ABB be
liable for incidental or consequential damages arising from use of any software or hard-
ware described in this document.
This document and parts thereof must not be reproduced or copied without written per-
mission from ABB, and the contents thereof must not be imparted to a third party nor used
for any unauthorized purpose.
The software or hardware described in this document is furnished under a license and
may be used, copied, or disclosed only in accordance with the terms of such license.
This product meets the requirements specified in EMC Directive 89/336/EEC and in Low
Voltage Directive 72/23/EEC.
Copyright © 2003 - 2004 by ABB.

All rights reserved.
Release: October 2004

Document number: 3BSE 020 926R4001
TRADEMARKS
Registrations and trademarks used in this document include:
Windows Registered trademark of Microsoft Corporation.
Industrial IT Trademark of ABB.
Advant Registered trademark of ABB.
Advant Fieldbus Trademark of ABB.
PROFIBUS Registered trademark of Profibus International (P.I.)
PROFIBUS-DP Registered trademark of Profibus International (P.I.)
HART Registered trademark of HART Communication Foundation.

TABLE OF CONTENTS
About This Book

0.1 General ......................................................................................................................11
0.2 Use of Warning, Caution, Information, and Tip Icons ..............................................12
0.3 Terminology...............................................................................................................13
0.4 Applicable Specifications ..........................................................................................14
0.5 Related Documentation .............................................................................................15
Section 1 - Introduction
1.1 Product Overview......................................................................................................18
1.1.1 Product Scope..............................................................................................18
1.1.1.1 CI801 Fieldbus Communications Interface (FCI)...................18
Section 2 - Installation ......................................................................................29
Section 3 - Configuration
3.1 CI801 FCI ..................................................................................................................31
3.1.1 Address Switches ........................................................................................31
3.1.2 PROFIBUS Connection ..............................................................................32
3.1.3 Power Supply Connections .........................................................................34
3.2 CI830 FCI ..................................................................................................................35
3.2.1 Address Switches ........................................................................................35
3.2.2 PROFIBUS-DP Connections ......................................................................35
3.2.3 Power Supply Connections .........................................................................38
3BSE 020 926R4001 5

Table of Contents
3.3 CI840 FCI.................................................................................................................. 39

3.3.1 Address Switches ........................................................................................ 39
3.3.2 PROFIBUS Connections ............................................................................ 40
3.3.3 Power Supply Connections ......................................................................... 42
3.4 Configuration and Performance ................................................................................ 43
3.4.1 CI801 Configuration Rules ......................................................................... 43
3.4.4 Supported I/O Modules and Drives via PROFIBUS and CI801 ................ 55
3.4.5 Supported I/O Modules and Drives via PROFIBUS and CI830 ................ 55
3.4.6 Supported I/O Modules via PROFIBUS and CI840 ................................... 56
3.4.7 Data Scanning ............................................................................................. 57
Section 4 - Operation
4.1 Operating Overview .................................................................................................. 61
4.2 Getting Started .......................................................................................................... 61
4.2.1 Functional Description................................................................................ 61
4.2.1.1 Module Configuration and Supervision.................................. 62
4.2.1.2 Signal Conditioning ................................................................ 62
4.2.1.3 Dynamic Data Transfer ........................................................... 62
4.2.1.4 Data Scanning Principles ........................................................ 64
4.2.1.5 Redundant FCI ........................................................................ 64
4.2.1.6 Hot Configuration In Run ....................................................... 64
4.2.2 I/O Module Functionality ........................................................................... 65
4.2.2.1 Module Identity....................................................................... 65
4.2.2.2 Module States ......................................................................... 66
4.2.2.3 Init State .................................................................................. 67
4.2.2.4 Not Configured State .............................................................. 67
4.2.2.5 Ready State ............................................................................. 67
4.2.2.6 Operational State..................................................................... 67
4.2.2.7 OSP (Outputs Set as Predefined) State ................................... 68
4.2.2.8 Error State ............................................................................... 68
4.2.2.9 Configuration, Parameters ...................................................... 68
6 3BSE 020 926R4001

Table of Contents
4.2.2.10 Loading Parameters...............................................................69

4.2.2.11 Loading Invalid Parameters...................................................69
4.2.2.12 Non-volatile Parameters........................................................69
4.2.2.13 OSP-Watchdog ......................................................................69
Section 5 - Maintenance
5.1 Preventive Maintenance ............................................................................................71
5.2 Hardware Indicators ..................................................................................................71
5.2.1 CI801 FCI Module LEDs............................................................................71
5.3 Error Messages ..........................................................................................................77
5.4 Fault Finding and User Repair ..................................................................................77
5.4.1 Communication Module Replacement........................................................77
5.4.1.1 General ....................................................................................77
5.4.1.2 Practical Execution..................................................................78
5.4.1.3 Additional Aspects on Individual S800 Communications
Modules ........................................................................78
5.4.2 Application Memory Reset .........................................................................81
5.4.3 CI801 Firmware version .............................................................................81
5.4.4 CI840 Firmware version .............................................................................82
5.5 Backup/Restore Procedures.......................................................................................83
5.5.1 Load the CI801 Software Upgrade .............................................................83
5.5.1.1 Connection ..............................................................................83
5.5.1.2 Loading the BASE Software, single FCI ................................84
5.5.1.3 What to do in Case of Problems? ............................................84
5.5.2.1 Reset of the CI830 Application Memory ................................85
5.5.2.2 Connection ..............................................................................85
5.5.2.3 Loading the BASE Software ...................................................85
5.5.2.4 What to do in Case of Problems? ............................................86
5.5.3.1 Connection ..............................................................................87
3BSE 020 926R4001 7

Table of Contents
5.5.3.2 Loading the BASE Software, single FCI................................ 87

5.5.3.3 Loading the BASE Software in the Backup FCI when
the Primary is Running................................................. 87
5.5.3.4 What to do in Case of Problems?............................................ 89
Appendix A - Specifications
A.1 CI801 Fieldbus Communications Interface (FCI).................................................... 91
A.1.1 Features ...................................................................................................... 91
A.1.2 Description ................................................................................................. 91
A.1.3 Technical Data............................................................................................ 93
A.1.4 Dimensions ................................................................................................ 94
A.1.5 Connections................................................................................................ 95
A.1.6 Block Diagram CI801 ................................................................................ 96
A.2 CI830 Fieldbus Communications Interface (FCI).................................................... 97
A.2.1 Features ...................................................................................................... 97
A.2.2 Description ................................................................................................. 97
A.2.3 Technical Data............................................................................................ 99
A.2.4 Dimensions .............................................................................................. 100
A.2.5 Connections.............................................................................................. 101
A.2.6 Block Diagram CI830 .............................................................................. 103
A.3 CI840 Fieldbus Communications Interface (FCI).................................................. 104
A.3.1 Features .................................................................................................... 104
A.3.2 Description ............................................................................................... 104
A.3.3 Technical Data.......................................................................................... 107
A.3.4 Connections.............................................................................................. 108
A.3.5 Block Diagram CI840, single ModuleBus............................................... 109
A.3.6 Block Diagram CI840, dual ModuleBus ................................................. 110
A.4 TU846 Redundant MTU for CI840, dual ModuleBus ........................................... 111
A.4.1 Features .................................................................................................... 111
A.4.2 Description ............................................................................................... 111
A.4.3 Technical Data.......................................................................................... 112
A.4.4 Dimensions .............................................................................................. 113
A.4.5 Connections ............................................................................................ 114
8 3BSE 020 926R4001

Table of Contents
A.4.6 Block Diagram TU846 .............................................................................116

A.5 TU847 Redundant MTU for CI840, single ModuleBus.........................................117
A.5.1 Features ....................................................................................................117
A.5.2 Description ...............................................................................................117
A.5.3 Technical Data..........................................................................................118
A.5.4 Dimensions...............................................................................................119
A.5.5 Connections ............................................................................................120
A.5.6 Block Diagram TU847 .............................................................................122
INDEX ........................................................................................................................123
3BSE 020 926R4001 9

Table of Contents
10 3BSE 020 926R4001

About This Book
0.1 General
This book provides a description of the S800 field communication using
PROFIBUS-DP/DPV1. It provides instructions for site planning and installation,
start-up and shutdown procedures, and information regarding capacity and
performance. This book is not intended to be the sole source of instruction for the
S800 I/O system.
This section provides introductory and background information including
guidelines how to find information in the manual related documentation.
Section 1, Introduction provides a product and functional overview.
Section 2, Installation guides in installation
Section 3, Configuration will give you the information needed to obtain the desired
function. The main information is structured as follow:
• Design considerations and guidelines are given.
• Capacity and performance.
Section 4, Operation discusses the different start modes and operating modes of the
FCI.
Section 5, Maintenance focus is on fault finding supported by built in diagnostics
and use of system status displays in operator station and LEDs on the FCI.
Those people involved in system engineering should attend the applicable system
engineering or maintenance courses offered by ABB Automation University.
3BSE 020 926R4001 11

Use of Warning, Caution, Information, and Tip Icons About This Book
0.2 Use of Warning, Caution, Information, and Tip Icons

This publication includes Warning, Caution, and Information where appropriate
to point out safety related or other important information. It also includes Tip to
point out useful hints to the reader. The corresponding symbols should be
interpreted as follows:
Electrical warning icon indicates the presence of a hazard which could result in
electrical shock.
Warning icon indicates the presence of a hazard which could result in personal
injury.
Caution icon indicates important information or warning related to the concept

discussed in the text. It might indicate the presence of a hazard which could
result in corruption of software or damage to equipment/property.
Information icon alerts the reader to pertinent facts and conditions.
Tip icon indicates advice on, for example, how to design your project or how to
use a certain function
Although Warning hazards are related to personal injury, and Caution hazards are
associated with equipment or property damage, it should be understood that
operation of damaged equipment could, under certain operational conditions, result
in degraded process performance leading to personal injury or death. Therefore,
comply fully with all Warning and Caution notices.
12 3BSE 020 926R4001

About This Book Terminology
0.3 Terminology
The following is a list of terms associated with Fieldbus Communication Interface
for PROFIBUS-DP/DPV1 that you should be familiar with. The list contains terms
and abbreviations that are unique to ABB or have a usage or definition that is
different from standard industry usage.
Term Description
Base cluster Consists of single or red. FCIs plus I/O modules
connected directly to the FCI.
FCI The Fieldbus Communication Interface (FCI) device
contains the interface to the fieldbus PROFIBUS-
DP/DPV1, ModuleBus interface and power regulators.
The FCI module can manage 24 I/O devices (up to 12
directly and to the others in 1 to 7 I/O clusters).
HCIR Hot Configuration In Run, possibility to change
configuration in a running system.
I/O cluster An extension of the I/O Station’s ModuleBus connected
to the FCI by fiber optic connections. Up to 12 I/O
devices per cluster.
I/O device A complete I/O device consists of one MTU and one I/O
module.
I/O module Is an active, electronic and signal conditioning unit. Can
be a part of an I/O device or a S800L I/O module.
I/O station An I/O station consists of a base cluster with single or
redundant FCI(s), 1-7 I/O clusters and up to 24 I/O
devices.
I.S. Intrinsic Safety is a protection technique to prevent
explosion in hazardous areas of a process plant.
ModuleBus Is an incremental, electrical or optical, bus for
interconnection of I/O devices.
(ModuleBus) Extension Is used when extending the electrical ModuleBus (within
cable the max. 2.5 meters 8.2”).
3BSE 020 926R4001 13

Applicable Specifications About This Book
Term Description
MTU The Module Termination Unit is a passive base unit
containing process terminals and a part of the
ModuleBus.
OSP Outputs Set as Predetermined. A user configurable
action on an output module when communications is lost
to the FCI or Controller.
PROFIBUS-DP PROFIBUS-DP is a fieldbus standard.
PROFIBUS-DPV1 PROFIBUS-DPV1 is a fieldbus standard.
PROFIBUS Stands for both PROFIBUS-DP and PROFIBUS-DPV1.
TC Thermocoupler
0.4 Applicable Specifications

This product meets the requirements specified in EMC Directive 89/336/EEC and in
Low Voltage Directive 72/23/EEC.
14 3BSE 020 926R4001

About This Book Related Documentation
0.5 Related Documentation

The following is a listing of documentation related to Fieldbus Communication
Interface for PROFIBUS-DP.
Title Description
S800 I/O General Information and Describes the general installation and
Installation configuration information for the S800
I/O system
S800 I/O Modules and Termination Units Describes the I/O modules and
termination units in the S800 I/O system
S800 I/O Modules and Termination Units Describes I/O modules and termination
with Intrinsic Safety Interface units with I.S. interface in the S800 I/O
system
S800 I/O PROFIBUS FCI Describes the memory mapping on
Memory Maps for CI801 PROFIBUS-DPV1 in CI801 for the S800
I/O system.
Memory Maps for CI830 PROFIBUS-DP in CI830 for the S800
I/O system.
Memory Maps for CI840 PROFIBUS-DPV1 in CI840 for the S800
I/O system.
3BSE 020 926R4001 15

Related Documentation About This Book
16 3BSE 020 926R4001

Section 1 Introduction
The S800 I/O is distributed modular I/O which communicates with numerous
controllers over a Advant Fieldbus 100 (AF100), PROFIBUS-DP/DPV1 or directly.
The S800 I/O provides easy installation of the I/O modules and process cabling. It is
highly modularized and flexible so that I/O modules can be combined to suit many
applications. The S800 I/O can be mounted in many configurations to fit most
requirements.
Figure 1-1 S800 I/O Fieldbus Communication Interface with an I/O Module on
Compact and Extended MTUs
3BSE 020 926R4001 17

Product Overview Section 1 Introduction
1.1 Product Overview

The S800 I/O provides easy installation of the I/O modules and process cabling. It is
highly modularized and flexible so that the I/O modules can be combined to suit
many applications. The S800 I/O modules and a Fieldbus Communication Interface
(FCI) are combined to form an I/O Station.
For more overview information please see the S800 I/O General Information and
Installation manual.
1.1.1 Product Scope
1.1.1.1 CI801 Fieldbus Communications Interface (FCI)

The CI801 Fieldbus Communication Interface (FCI) module is a configurable
communication interface which performs operations such as signal processing,
gathering of various supervision information, OSP handling and configuration of
I/O modules. The FCI connects to a controller by way of the PROFIBUS-DPV1
fieldbus.
The FCI has one PROFIBUS-DPV1 interface and uses a PROFIBUS-DPV1 cable
with a total length of up to 1200 meters (1312 yards). Up to 32 stations can be
configured on one segment. The station address sets by rotary switches that select
the address on the fieldbus in the range of 01 to 99.
The FCI modules are DIN rail mounted and have connections for input power,
PROFIBUS-DPV and two rotary switches for station address selection.
An I/O Station can consist of the FCI modules, ModuleBus Modems and the I/O
modules. The FCI is the bus-master on the S800 I/O ModuleBus and communicates
with the S800 I/O modules. It is a pure “slave station” on PROFIBUS-DPV1 which
is controlled by a master station.
I/O Station modules are mounted on DIN rails and are connected by the
ModuleBus. Figure 1-2 shows the FCI modules connected to the Optical
ModuleBus Port TB842.
18 3BSE 020 926R4001

Section 1 Introduction Product Scope
LED Status
Indicators
ModuleBus
Interface
Connector
Power Supply
Address
TB842 Switch #1
TB806
Address
PROFIBUS-DP Switch #2
Connector
Figure 1-2 CI801 FCI Module and TB842 Optical ModuleBus Port
The FCI communicates with the PROFIBUS Master, ModuleBus Modems and the
I/O modules. The FCI handles the I/O-modules operations such as read and write
data, read status and configuration of modules and channels. The FCI has a
connection to the TB842 Optical ModuleBus Port mounted on a TB806 to the left,
see Figure 1-2.
3BSE 020 926R4001 19

Product Scope Section 1 Introduction
The FCI provides 24 V d.c. (from the source) and an isolated 5 V dc power to the
base cluster’s I/O modules (12 maximum) by way of the ModuleBus connections.
One power source 24 V d.c. can be connected to the power terminals (L+ & L-).
The power source is supervised by the POWER OK status LED.
The size, type and direction of data to be transferred on the PROFIBUS-DP bus
depends on and is determined by the I/O module type. The FCI can be configured to
send or transmit dynamic data over the PROFIBUS-DP with cycle times in the
interval from 1 ms.

communication interface for single configurations which performs operations such
as signal processing, gathering of various supervision information, OSP handling
and configuration of I/O modules. The FCI connects to a controller by way of the
PROFIBUS-DP fieldbus.
The FCI has one PROFIBUS-DP interface and uses a PROFIBUS-DP cable with a
total length of up to 1200 meters (1312 yards). Up to 32 stations can be configured
on one segment. The FCI has two rotary switches that select its address on the
fieldbus in the range of 01 to 79.
An I/O Station can consist of the FCI module, ModuleBus Modems and the I/O
with the S800 I/O modules. It is a pure “slave station” on PROFIBUS-DP which is
controlled by a master station.
ModuleBus. This principle allows horizontal and vertical mounting on the wall.
Figure 1-3 shows the FCI Module.
connector for the TB810/TB811 Optical ModuleBus Port.
20 3BSE 020 926R4001

LED Status
F R Indicators
P
RX TX
PROFIBUS ModuleBus
DIN Rail Interface
Connector
SERVICE
STN. ADDR.
4 56 Address
3 7 x 10
2 8 Switch #1
109 (Address 04
4 56
3 7x1 Address shown)
CI830 2
109
8 Switch #2
Service Port
Label SWX.X/Y
PROFIBUS Tx Rx
software Connector for the
version L+ TB810/TB811
L- Tx Optical ModuleBus Port
Power Supply SA Interface
Connections
SB Rx
PROFIBUS-DP
Connector
Figure 1-3 CI830 FCI Module
3BSE 020 926R4001 21

base cluster’s I/O modules (12 maximum) by way of the ModuleBus connections.
One power source (single or redundant 24 V d.c.) can be connected to the power
terminals (L+ & L-) of the FCI.
1:1 redundant power sources can be supervised by connecting the power sources
POWER OK status signals to terminals SA and SB.
interval from 1 ms.
Figure 1-4 CI830 FCI Dimensions
22 3BSE 020 926R4001


communication interface which performs operations such as signal processing,
gathering of various supervision information, OSP handling and configuration of
I/O modules. The FCI connects to a controller by way of the PROFIBUS-DPV1
fieldbus.
CI840 is designed for redundant applications. One CI840 works as a primary FCI
and the other as a backup. Both FCIs supervises each other. If a fault occurs in the
primary FCI, it results in an automatic switch over to the backup CI840.
The FCI has one PROFIBUS-DPV1 interface and uses a PROFIBUS-DPV1 cable
with a total length of up to 1200 meters (1312 yards). Up to 32 stations can be
configured on one segment. The station address sets by rotary switches that select
the address on the fieldbus in the range of 01 to 99, in redundant configurations
1 to 62.
The FCI modules are mounted on a Module Termination Unit TU846 or TU847.
TU846/TU847 are DIN rail mounted and have connections for input power,
PROFIBUS-DPV, service tool and two rotary switches for station address selection.
TU847 with CI840 are used for single I/O applications and TU846 with CI840 are
used for redundant applications.
An I/O Station can consist of the FCI modules, ModuleBus Modems and the I/O
with the S800 I/O modules. It is a pure “slave station” on PROFIBUS-DPV1 which
is controlled by a master station.
ModuleBus. Figure 1-5 shows the FCI modules mounted on a Module Termination
Unit TU847 and connected to the Optical ModuleBus Port TB842. Figure 1-6
shows the FCI modules mounted on TU846 and connected to the Optical
ModuleBus Port TB842.
3BSE 020 926R4001 23

F F LED Status
R R Indicators
P P
Rx/Tx Rx/Tx
PRIM PRIM
DUAL DUAL ModuleBus
Interface
Connector
Address
Switch #1
(Address 66
1 shown)
Address
CI840 CI840
Switch #2
TB842
TB806
Power Supply Service

Connections Ports
PROFIBUS-DP
Connector
Figure 1-5 CI840 FCI Module, TU847 Termination Unit and TB842 Optical
ModuleBus Port
24 3BSE 020 926R4001

Figure 1-6 CI840 FCI Module, TU846 Termination Unit and TB842 Optical
ModuleBus Port
3BSE 020 926R4001 25

connection to the TB842 Optical ModuleBus Port.
base cluster’s I/O modules (12 maximum or 6 pairs) by way of the ModuleBus
connections. One power source (single or redundant 24 V d.c.) can be connected to
the power terminals (L+ & L-) of the MTU.
1:1 redundant power sources can be supervised by connecting the power sources
POWER OK status signals to terminals SA and SB.
interval from 1 ms.
For CI840 FCI and TU846/TU847 dimensions, see Figure 1-7 and Figure 1-8.
26 3BSE 020 926R4001

Figure 1-7 TU847 Dimensions (Same Dimensions for TU846)
3BSE 020 926R4001 27

128 mm
(5.04”)
47 mm
(1.85”)
124 mm (4.88”)
162,9 mm
(6.41”) 186,5 mm
(7.34”)
Figure 1-8 CI840 FCI and TU847 Terminal Unit Dimensions (Same Dimensions for
TU846)
28 3BSE 020 926R4001

Section 2 Installation
Please, see the S800 I/O General Information and Installation manual.
For PROFIBUS, see Technical Guideline, Installation Guideline for
PROFIBUS-DP/FMS (Order No.2.112).
3BSE 020 926R4001 29

Section 2 Installation
30 3BSE 020 926R4001

Section 3 Configuration
3.1 CI801 FCI

The FCI needs to be connected to the PROFIBUS-DPV1 and have an address
selected. It is also connected to a 24 V d.c. power source to provide power to the I/O
Station. Also refer to Configuration and Performance on page 43 for information on
how to estimate the fieldbus and power loading of each I/O station configuration.
3.1.1 Address Switches

The CI801 is equipped with two rotary switches used as station address selectors for
PROFIBUS-DPV1 connection. The station address can be set in the range of
01 to 99. There can be up to 32 stations per PROFIBUS-DPV1 segment. Figure 3-1
shows the front panel of the CI801.
Address
Switch #1
Address
Switch #2
Figure 3-1 CI801 Front Panel
3BSE 020 926R4001 31

PROFIBUS Connection Section 3 Configuration
3.1.2 PROFIBUS Connection

The FCI connects to the PROFIBUS via the 9 pin D-way connector on the front.
This allows the FCI (if not the last one at the PROFIBUS segment) to be removed
from the PROFIBUS without disconnecting the other nodes of the fieldbus. If
CI801 is the last module at a PROFIBUS segment and supplies an active
termination in the cable connector, disconnection of the power supply or the
PROFIBUS cable from CI801 can not be done without disrupting the bus.
See Figure 3-2 for CI801 connection details.
Profibus Cable
Figure 3-2 CI801 FCI PROFIBUS Terminal Connections
32 3BSE 020 926R4001

Section 3 Configuration PROFIBUS Connection
Table 3-1 shows the fieldbus connection assignments.
Table 3-1 FCI PROFIBUS Connections
Pin Designation Description

1 Shield Shield/protective ground
2 - Not used
3 RxD/TxD-P Receive/Transmit data - plus
4 RTS Direction control (optional)
5 DGND Data ground
6 VP Supply voltage for the
terminating resistors
7 - Not used
8 RxD/TxD-N Receive/Transmit data -
minus
9 DGND Data ground (if RTS is used)
3BSE 020 926R4001 33

Power Supply Connections Section 3 Configuration
3.1.3 Power Supply Connections

The FCI requires 24 V d.c. (19.2 - 30 V) with a maximum current requirement of
2.3 Ampere. See Figure 3-3 for power supply connections.
0 V d.c.
+24 V d.c.
Figure 3-3 CI801 FCI Power Supply Connections
The incoming power can then be distributed to other FCIs or the I/O modules if
desired. Refer to S800 I/O General Information and Installation for power supply
connection diagrams.
Power connections can accept 0.2 - 2.5 mm2 (24 - 14 AWG) wire size.
FCI power supply connections are presented in Table 3-2:
Table 3-2 FCI Power Connection Terminal

1 L+ +24 V d.c. Supply
2 L- 0 V d.c. Supply
34 3BSE 020 926R4001

Section 3 Configuration CI830 FCI
3.2 CI830 FCI

The FCI needs to be connected to the PROFIBUS-DP and have an address selected.
It is also connected to a 24 V d.c. power source to provide power to the I/O Station.
Also refer to Configuration and Performance on page 43 for information on how to
estimate the fieldbus and power loading of each I/O station configuration.

The CI830 is equipped with two rotary switches used as station address selectors for
PROFIBUS-DP connection. The station address can be set in the range of 01 to 79.
There can be up to 32 stations per PROFIBUS-DP segment. Figure 3-4 shows the
front panel of the CI830.
SERVICE
STN. ADDR.
4 56 Address
3 7 x 10
2 8 Switch #1
109 (Address 04
5
4 6 shown)
3 7x1 Address
CI830
2
109
8 Switch #2
SWX.X/Y PROFIBUS Tx Rx
L+
Tx
L-
SA
Figure 3-4 Front Panel of the CI830 FCI
3.2.2 PROFIBUS-DP Connections

The FCI connects to the PROFIBUS-DP via the 9 pin D-way connector on the front.
This allows the FCI (if not the last one at the PROFIBUS segment) to be removed
from the PROFIBUS-DP without disconnecting the other nodes of the fieldbus.
If CI830 is the last module at a PROFIBUS segment and supplies an active
3BSE 020 926R4001 35

PROFIBUS-DP Connections Section 3 Configuration

3 7x1
2 8
CI830 109
PROFIBUS Tx Rx
FCI L+
Tx
L-
SA
SB Rx
Profibus Cable
Figure 3-5 CI830 FCI PROFIBUS-DP Terminal Connections
36 3BSE 020 926R4001

Section 3 Configuration PROFIBUS-DP Connections
Table 3-3 FCI PROFIBUS-DP Connections

2 - Not used
4 - Not used
5 DGND Data ground
7 - Not used
minus
9 - Not used
3BSE 020 926R4001 37


109
4 56
3 7x1
2 8
CI830 109
+24 V d.c.
PROFIBUS Tx Rx
0 V d.c.
L+
Power Supply Tx
“A” Monitor L-
SA
Power Supply SB Rx
“B” Monitor
Figure 3-6 FCI Power Supply Connections

3 SA Redundant Power Supply Monitoring Input
4 SB Redundant Power Supply Monitoring Input
38 3BSE 020 926R4001

Section 3 Configuration CI840 FCI
3.3 CI840 FCI

The FCI needs to be connected to the PROFIBUS-DPV1 and have an address
selected. It is also connected to a 24 V d.c. power source to provide power to the I/O
Station. Also refer to Configuration and Performance on page 43 for information on
how to estimate the fieldbus and power loading of each I/O station configuration.

The TU846/TU847 is equipped with two rotary switches used as station address
selectors for PROFIBUS-DPV1 connection. 0-62 are allowed for redundant FCI
connections and 0-99 are allowed for single connections. The FCI in position B will
not start when addresses between 63 and 99 are used. There can be up to 32 stations
per PROFIBUS-DPV1 segment. Figure 3-7 shows the front panel of the
TU846/TU847.
CI840 CI840
Address
Switch #1
Address
Switch #2
Figure 3-7 TU846/TU847 Front Panel
3BSE 020 926R4001 39

PROFIBUS Connections Section 3 Configuration
3.3.2 PROFIBUS Connections

The FCI connects to the PROFIBUS via the 9 pin D-way connector on the front of
TU846/TU847. This allows the FCI (if not the last one at the PROFIBUS segment)
to be removed from the PROFIBUS without disconnecting the other nodes of the
fieldbus. If CI840 is the last module at a PROFIBUS segment and supplies an active
CI840 CI840
Profibus Cables
Figure 3-8 CI840 FCI PROFIBUS Terminal Connections
40 3BSE 020 926R4001

Section 3 Configuration PROFIBUS Connections
Table 3-5 FCI PROFIBUS Connections

2 - Not used
5 DGND Data ground
7 - Not used
minus
3BSE 020 926R4001 41


CI840 CI840
+24 V d.c.
0 V d.c.
Power Supply
“A” Monitor
Power Supply
“B” Monitor
Figure 3-9 FCI Power Supply Connections

3 SA Redundant Power Supply Monitoring Input
4 SB Redundant Power Supply Monitoring Input
42 3BSE 020 926R4001

Section 3 Configuration Configuration and Performance
3.4 Configuration and Performance

3.4.1 CI801 Configuration Rules
The maximum number of S800 I/O stations per bus is: 99 stations
Supported communication speeds: 93.75 kbit/s to 12 Mbit/s
The maximum number of S800 I/O stations per bus segment is: 32 stations
The maximum number of I/O modules in a station is: 24 modules
The maximum number of I/O modules per cluster is: 12 modules
Due to the PROFIBUS-DPV1 specification it is not possible to always connect 24
I/O modules to one FCI. The reason is that the S800 I/O system includes more data
and user parameters than PROFIBUS-DPV1 can handle. Table 3-7 shows maximum
number of I/O modules that can be connected to one CI801.
Table 3-7 Maximum Number of Modules on CI801
Module Type Number of Modules

AI801, AI810, AI830, 14
AI835, AI890, AI893,
AI895
AI820 24
AI843 11
AI845 14
AO801, AO810, 7
AO890, AO895
AO820 14
AO845 7
DI840 17
DI8XX 24
DO801, DO810, DO814 22
3BSE 020 926R4001 43

CI801 Configuration Rules Section 3 Configuration
Table 3-7 Maximum Number of Modules on CI801 (Continued)

DO840 20
All other DO8XX 24
DP820 8
DP840 7
Standard Drives 9
In order to find out if a given configuration of analog and digital modules can be
used the following method should be used:
• Fill in number of modules in table Table 3-8.
• Calculate the sum in the three columns:
– Sum User Parameters
– Sum Input Bytes
– Sum Output Bytes.
• Calculate the three total sums for:
– ParamSize
– InSize
– OutSize.
• Check that:
– ParamSize is less than or equal to 221 (220 if HCIR is used)
– InSize is less than or equal to 239
– OutSize is less than or equal to 112.
If any of these three values is too high then the configuration can not be used.
44 3BSE 020 926R4001

Section 3 Configuration CI801 Configuration Rules
Table 3-8 Calculation of Number of Modules on CI801
Number Sum Sum Sum

Module User Input Output
of User Para- Input Output
Type Parameters Bytes Bytes
Modules meters Bytes Bytes
AI801 13 17 0
AI810 13 17 0
AI820 9 9 0
AI830 12 17 0
AI835 15 17 0
AI843 16 20 2
AI845 13 17 -
AI890 13 17 0
AI893 15 17 0
AI895 13 17 0
AO801 17 1 16
AO810 17 1 16
AO820 11 1 8
AO845 18 1 16
AO890 17 1 16
AO895 17 1 16
DI801 7 4 0
DI802 6 2 0
DI803 6 2 0
DI810 7 4 0
DI811 7 4 0
3BSE 020 926R4001 45

Table 3-8 Calculation of Number of Modules on CI801 (Continued)
Number Sum Sum Sum

DI814 7 4 0
DI820 6 2 0
DI821 6 2 0
DI840 13 4 0
DI890 7 2 0
DO801 10 2 2
DO802 7 1 1
DO810 10 2 2
DO814 10 2 2
DO815 8 1 1
DO820/821 7 1 1
DO840 11 2 2
DO890 6 1 1
DP820 12 18 13
DP840 10 34 0
Standard 4 13 12
Drives
Total sum - - - ParamSize InSize OutSize
46 3BSE 020 926R4001


The maximum number of S800 I/O stations per bus is: 99 stations.
Supported communication speed: 9.6 kbits/s to 12 Mbit/s.
The maximum number of S800 I/O stations per bus segment is: 32 stations.
Due to the PROFIBUS-DP specification it is not possible to always connect 24 I/O
modules to one FCI. The reason is that the S800 I/O system includes more data and
user parameters than PROFIBUS-DP can handle. Table 3-9 shows maximum
number of I/O modules that can be connected to one CI830.

AI801, AI810, AI830, 12
AI835, AI890, AI893
AI820 20
AO801, AO810, AO890 13
AO820 21
DP820 11
DP840 6
All DI and DO modules 24
Standard Drives 17/24(1)
(1) See Table 3-10.
3BSE 020 926R4001 47

– Sum Input Bytes
– ParamSize
– InSize
– OutSize.
• Check that:
– ParamSize is less than or equal to 237
• Round up the values InSize, OutSize and the sum of ParamSize+15 to the
nearest multiple of eight (8), for example, 233 is rounded to 240.
• Finally calculate the memory size with the formula:
MemSize =a + 2xRoundParamSize + 3x(RoundInSize +RoundOutSize).
a=656 for firmware release 1.0 and 1.1.
a=728 for firmware release 1.2 or later.
Check that MemSize is less than or equal to 2048. If not, the configuration can
not be used.
Data with * are valid for CI830 firmware 1.0 to 1.2.

Data inside parenthesis ( ) are valid for CI830 firmware version 1.3 or higher.
48 3BSE 020 926R4001

Sum
User Number Sum Sum
Module Input Output User
Paramete of Input Output
Type Bytes Bytes Para-
rs Modules Bytes Bytes
meters
CI830 3 4 0 1 3 4 0
AI801 7 20 4
AI810 11 20 4
AI820 7 12 4
AI830 11 20 4
AI835 13 20 4
AI890 7 20 4
AI893 13 20 4
AO801 16 4 18
AO810 16 4 18
AO820 10 4 10
AO890 16 4 18
DI801 4 6 4
DI802 4 6 2
DI803 4 6 2
DI810 4 6 4
DI811 4 6 4
DI814 4 6 4
DI820 4 6 2
DI821 4 6 2
3BSE 020 926R4001 49

Sum
User Number Sum Sum
Module Input Output User
Paramete of Input Output
Type Bytes Bytes Para-
rs Modules Bytes Bytes
meters
DI890 4 6 4
DO801 8 4 4
DO802 6 4 4
DO810 8 4 4
DO814 8 4 4
DO815 6 4 4
DO820/821 6 4 4
DO890 5 4 4
DP820 11 22 16
DP840 7 36 4
Standard 3* 14* 12*
Drives (4) (8) (6)
Total sum - - - ParamSiz InSize OutSize
e
Rounded - - - Round Round Round

sum ParamSiz InSize OutSize
e
Data with * are valid for CI830 firmware 1.0 to 1.2.

Data inside parenthesis ( ) are valid for CI830 firmware version 1.3 or higher.
50 3BSE 020 926R4001


The maximum number of S800 I/O stations per bus is:
Redundant CI840: 62 stations
Single CI840: 99 stations
Supported communication speeds: 93.75 kbit/s to 12 Mbit/s
The maximum number of S800 I/O stations per bus segment is:
Communication speed 12Mbit/s: 20 stations
Communication speed <1.5Mbit/s or less: 32 stations
Due to the PROFIBUS-DPV1 specification it is not possible to always connect 24
I/O modules to one FCI. The reason is that the S800 I/O system includes more data
and user parameters than PROFIBUS-DPV1 can handle. Table 3-11 shows
maximum number of I/O modules that can be connected to one CI840.

AI801, AI810, AI830, 14
AI835, AI890, AI893,
AI895
AI820 24
AI843 11
AI845 14
AO801, AO810, 7
AO890, AO895
AO820 14
AO845 7
DI8XX 24
DI840 17
3BSE 020 926R4001 51

Table 3-11 Maximum Number of Modules on CI840 (Continued)

DO801, DO810, DO814 22
DO840 20
All other DO8XX 24
DP820 8
DP840 7
– Sum Input Bytes
– ParamSize
– InSize
– OutSize.
• Check that:
– ParamSize is less than or equal to 221 (220 if HCIR is used)
52 3BSE 020 926R4001

Number Sum Sum Sum

AI801 13 17 0
AI810 13 17 0
AI820 9 9 0
AI830 12 17 0
AI835 15 17 0
AI843 16 20 2
AI845 13 17 -
AI890 13 17 0
AI893 15 17 0
AI895 13 17 0
AO801 17 1 16
AO810 17 1 16
AO820 11 1 8
AO845 18 1 16
AO890 17 1 16
AO895 17 1 16
DI801 7 4 0
DI802 6 2 0
DI803 6 2 0
DI810 7 4 0
DI811 7 4 0
3BSE 020 926R4001 53

Number Sum Sum Sum

DI814 7 4 0
DI820 6 2 0
DI821 6 2 0
DI840 13 4 -
DI890 7 2 0
DO801 10 2 2
DO802 7 1 1
DO810 10 2 2
DO814 10 2 2
DO815 8 1 1
DO820/821 7 1 1
DO840 11 2 2
DO890 6 1 1
DP820 12 18 13
DP840 10 34 0
Total sum - - - ParamSize InSize OutSize
54 3BSE 020 926R4001

Section 3 Configuration Supported I/O Modules and Drives via PROFIBUS and CI801
3.4.4 Supported I/O Modules and Drives via PROFIBUS and CI801
The following I/O modules are supported by the PROFIBUS Field
Communication Interface module CI801:
• AI801, AI810, AI820, AI830, AI835, AI843, AI845, AI890, AI893, AI895
• AO801, AO810, AO820, AO845, AO890, AO895
• DI801, DI802, DI803, DI810, DI811, DI814, DI820, DI821, DI840 (SOE
handling not supported), DI890
• DO801, DO802, DO810, DO814, DO815, DI820, DO821, DO840, DO890
• DP820, DP840
• ABB Standard Drives. Have to be connected via TB820.
– ACS600/ACS800 with standard application
– ACS600/ACS800 with crane application
– ACS600/ACS800 with pump and fan application (PFC)
– ACS400/ACS500/DCS400 with standard drive
3.4.5 Supported I/O Modules and Drives via PROFIBUS and CI830
• AI801, AI810, AI820, AI830, AI835, AI890, AI893
• AO801, AO810, AO820, AO890
• DI801, DI802, DI803, DI810, DI811, DI814, DI820, DI821, DI890
• DO801, DO802, DO810, DO814, DO815, DI820, DO821, DO890
• DP820, DP840
• ABB Standard Drives
– ACS600/ACS800 with standard application
– ACS600/ACS800 with crane application
– ACS600/ACS800 with pump and fan application (PFC)
– ACS400/ACS500/DCS400 with standard drive
3BSE 020 926R4001 55

Supported I/O Modules via PROFIBUS and CI840 Section 3 Configuration
3.4.6 Supported I/O Modules via PROFIBUS and CI840

• AI801, AI810, AI820, AI830, AI835, AI843, AI845, AI890, AI893, AI895
• AO801, AO810, AO820, AO845, AO890, AO895
• DI801, DI802, DI803, DI810, DI811, DI814, DI820, DI821, DI840 (SOE
handling not supported), DI890
• DO801, DO802, DO810, DO814, DO815, DI820, DO821, DO840, DO890
• DP820, DP840
56 3BSE 020 926R4001

Section 3 Configuration Data Scanning
3.4.7 Data Scanning

ModuleBus data is scanned (read or written) cyclically, depending on the I/O
module configuration. To calculate the I/O scan cycle time in the FCI do as follows:
Totalize (number of module type x) * (used execution time for type x)
(see Table 3-13) if the value is a multiple of 2 add 2 to the value. Otherwise increase
the total value to the nearest higher multiple of two (2) to get the I/O scan cycle
time.
Table 3-13 I/O Scan Cycle Time in the FCI
Execution Time Used in ms

CI840
Module Type
CI801 CI830 Redundant
Single I/O
I/O pair
AI801, AI810, AI890, AI895 3.00 3.00 3.00 -
AI820 1.50 1.50 1.50 -
AI830, AI835, AI893 0.40 0.40 0.40 -
AI843 0.40 - 0.40 0.80
AI845 3.00 - 3.00 6.00
AO801, AO810, AO890, AO895 1.20 1.20 1.20 -
AO820 0.60 0.60 0.60 -
AO845 1.20 - 1.20 2.40
DI801, DI802, DI803, DI810, DI811, 0.43 0.43 0.43 -
DI814, DI820, DI821
DI840 0.43 - 0.43 0.86
DI890 0.43 0.43 0.43 -
DO801, DO802, DO810, DO814, 0.43 0.43 0.43 -
DO815, DO820, DO821
DO840 0.43 - 0.43 0.86
3BSE 020 926R4001 57

Data Scanning Section 3 Configuration
Table 3-13 I/O Scan Cycle Time in the FCI (Continued)
Execution Time Used in ms

CI840
Module Type
CI801 CI830 Redundant
Single I/O
I/O pair
DO890 0.43 0.43 0.43 -
DP820 1.72 1.72 1.72 -
DP840 3.00 3.00 3.00 6.00
Engineered drives - 1.72 - -
Standard drives 0.71 0.86 - -
FCI CI801 1.18 - - -
FCI CI830 firmware 1.0 to 1.2 - 1.40 - -
FCI CI830 firmware 1.3 or later - 2.24 - -
FCI CI840 - - 1.18
Analog modules will be scanned every fourth I/O scan cycle time except for AI830
and AI835 modules which will be scanned every tenth time. DI, DO modules and
standard drives will be scanned each I/O scan cycle time.
58 3BSE 020 926R4001

Section 3 Configuration Data Scanning
For example, a non redundant station with CI830 with firmware 1.3, two AI810, one
AO810, two DI810, two DO820 and one AI830 will give the following I/O scan
cycle time:
2 AI810 => 2*3.00 ms = 6.00 ms
1 AO810 => 1*1.20 ms = 1.50 ms
2 DI810 => 2*0.43 ms = 0.86 ms
2 DO810 => 2*0.43 ms = 0.86 ms
1 AI830 =>1*0.40 ms = 0.40 ms
1 CI830A => 1*2,24 ms = 2.24 ms
------------------------------------------------------
11.86 ms
11.86 ms is not a multiple of 2, so increase of the value to the nearest multiple
of 2 gives 12 ms.
That will give an I/O scan cycle time of 12 ms between the FCI and its I/O
modules. This means that the DIs and DOs will be scanned every 12 ms, the
AI810s and the AO810 every (4*12 ms) 48ms and the AI830 every (10*12 ms)
120 ms.
Minimum I/O scan cycle time = 4 ms with firmware 1.0 to 1.2.
Minimum I/O scan cycle time = 6 ms with firmware 1.3 or later.
For example, a single station with CI801 or a redundant station with CI840, two
AI810, one AO810, two DI810, two DO820 and one AI830 will give the following
I/O scan cycle time:
2 AI810 => 2*3.00 ms = 6.00 ms
1 AO810 => 1*1.20 ms = 1.20 ms
2 DI810 => 2*0.43 ms = 0.86 ms
2 DO810 => 2*0.43 ms = 0.86 ms
1 AI830 => 1*0.40 ms = 0.40 ms
1 CI840 => 1*1.18 ms = 1.18 ms
------------------------------------------------------
10.50 ms
10.50 ms is not a multiple of 2, so increase of the value to the nearest multiple
of 2 gives 12 ms.
3BSE 020 926R4001 59

Data Scanning Section 3 Configuration
That will give an I/O scan cycle time of 12 ms between the FCI and its I/O
modules. This means that the DIs and DOs will be scanned every 12 ms,
the AI810s and the AO810 every (4*12 ms) 48 ms and the AI830 every
(10*12 ms) 120 ms.
Minimum I/O scan cycle time = 4 ms
60 3BSE 020 926R4001

Section 4 Operation
4.1 Operating Overview

An I/O station is an autonomous station which normally is not handled by an
operator. Of course, it is started and sometimes stopped manually. This is done,
however, in specific situations such as the time of installation work and
maintenance.
Accordingly, operating instructions are spread out in this manual. See where the
specific activity is treated.
For general descriptions, see the beginning of this section. For concrete instructions,
see Section 2, Installation and Section 5, Maintenance.
4.2 Getting Started

4.2.1 Functional Description
This section describes the functionality and services that the FCI (Fieldbus
Communication Interface) offers for a PROFIBUS Master via PROFIBUS-DP.
This includes a general description of the data flow on PROFIBUS-DP, and how the
S800 I/O modules are operated and treated.
The FCI acts as a pure slave station on PROFIBUS-DP. The FCI controls all
operations of an S800 I/O station. It is the bus-master on the S800 I/O ModuleBus.
It does this by handling all communications between the PROFIBUS Master and the
S800 I/O modules.
The FCI scans all dynamic input data from the input modules and sends it on
PROFIBUS-DP, and writes all dynamic output data received from PROFIBUS-DP
to the output modules.
3BSE 020 926R4001 61

Functional Description Section 4 Operation
The FCI is responsible for:

• Module configuration and supervision.
• Performing signal conditioning on input and output values.
• Dynamic data transfer.
4.2.1.1 Module Configuration and Supervision

The FCI stores the configuration for all configured I/O Modules in the station.
The FCI will continuously supervise all I/O modules being configured by the
PROFIBUS Master. It sends the status of all modules to the PROFIBUS Master via
PROFIBUS-DP.
When the FCI detects an I/O module without configuration, which it has
configuration data for, it will automatically load the parameters to the module.
The module is then automatically set into operation by the FCI.
4.2.1.2 Signal Conditioning

The FCI performs the signal conditioning (for example, linearization and filtering)
for the more basic I/O modules. This means that the FCI has to make some
computation before moving the value to the module or after reading the value from
the module. The type of signal conditioning to perform depends on the module type
and its configuration (parameter settings).
Intelligent I/O modules do signal conditioning themselves. In this case the FCI only
has to move the value to or from the module. This means less load on the FCI which
can be used on other modules or services.
4.2.1.3 Dynamic Data Transfer

Figure 4-1 gives an overview of how the exchange of dynamic process data is
transferred back and forth between the user application and the actual process.
The transportation of dynamic data between PROFIBUS-DP and the ModuleBus is
the main task for the FCI. The FCI has a dedicated memory area where it sends the
output values and reads the input values. The CPU in the FCI performs the rest of
the data transportation. It reads output values from the memory and writes to the I/O
Modules via the ModuleBus and vice versa.
62 3BSE 020 926R4001

Section 4 Operation Functional Description
Dynamic Data Exchange

PROFIBUS Master (Class 1)
The PROFIBUS Master uses Data Exchange

request towards the FCI according to it’s
scheduling scheme.
PROFIBUS-DP
3. 3 and 4
Data exchange with PROFIBUS-DP is
4. cyclic and consists of both writing of
data from Master to FCI as well as data
read from FCI to Master.
Fieldbus Communication
Interface (FCI)
Communication Memory
Input Module Output Module
2 and 5
Input and output values are updated 2. Chan x Chan x
as fast as possible (depends on the
configuration). Signal conditioning is 5. Values Values
also performed in this loop. 6.
1.
1 and 6
Input and output values are updated
“as fast as possible” (depends on the
S800 I/O module configuration).
P ro c e s s
Figure 4-1 Dynamic Data Exchange for PROFIBUS-DP in Runtime
3BSE 020 926R4001 63

Functional Description Section 4 Operation
4.2.1.4 Data Scanning Principles

The data transfer between PROFIBUS-DP and the ModuleBus is not synchronized.
Read and write operations are performed from and to a dual port memory in the
FCI.
The ModuleBus data is scanned (read or written) cyclically, depending on the I/O
module configuration. On one scan all digital modules, 1/4 of the analog modules
and 1/10 of the slow analog modules are scanned. It takes 4 scans to read all analog
modules and 10 scans to read all slow analog modules.
4.2.1.5 Redundant FCI

CI840 can work as a redundant pair where one FCI is primary and one is backup. As
long as the primary works correct it will handle both the PROFIBUS and the
ModuleBus. Both FCIs supervise each other. If a fault occurs in the primary the
backup will automatically take over.
4.2.1.6 Hot Configuration In Run

CI801 and CI840 supports the function Hot Configuration In Run (HCIR).
HCIR is a function for modifying field device configuration without disturbing the
running system. The following actions can be done:
• Delete modules
• Insert modules
• Parameter changes
During the configuration the values are frozen for a short moment. The time is
dependent of the PROFIBUS master, communication speed, CI801, CI840, type of
configuration and type of changes. Typical 300 ms at a communication speed of
1.5 MHz.
The configuration time is supervised by a watchdog. If the watchdog time elapse,
the outputs will go to OSP (Output Set as Predefined). The watchdog time consists
of two parts, one part calculated by the PROFIBUS master and one fix part for the
slave (CI801 and CI840 1200 ms).
64 3BSE 020 926R4001

Section 4 Operation I/O Module Functionality
4.2.2 I/O Module Functionality

All S800 I/O modules have some common functionality. This section describes
these common functions of the I/O modules.
An S800 I/O module complies with the following framework:
• General
– It has a Module Identity (see Module Identity on page 65).
– It has a state that can be controlled
(see Module States on page 66).
– It reports status for modules and channels.
• Parameters
– It may have configuration parameters for the module and the channels.
– It may have non-volatile parameters for each channel (factory settings).
• Dynamic values
– All channels have dynamic values including quality indications.
– All output channels can be read for verification of the performance and
health.
4.2.2.1 Module Identity

All S800 I/O modules contains a module identity. The module identity is used to
verify that an I/O module of the expected (user configured) type is mounted before
taking it operational. It protects the system from performing unexpectedly.
3BSE 020 926R4001 65

I/O Module Functionality Section 4 Operation
4.2.2.2 Module States

The figure below shows the states of the I/O modules.
NOT Reset AND 5 V OK
From ALL states:

Restart-Command
Init
Error
Not
Configured
From all other states:
Fatal error detected by module
Parameter loaded
Commanded to
Not Configured Ready
state
Commanded to Operational state

Commanded to
Operational state Ope-
rational
OSP Communication time-out
Output modules only
Figure 4-2 I/O Module States
66 3BSE 020 926R4001

The states are described in more detail below:
4.2.2.3 Init State

In the Init state the actual initialization of the module is performed, including a self-
test.
Inputs Not scanned
Outputs Inactive: 0 V
LEDs Fault
4.2.2.4 Not Configured State

In the Not Configured state the module waits to be configured. The FCI performs
the parameter download to the module.
Inputs Not scanned
Outputs Inactive:0 V
LEDs Fault until first ModuleBus dialog, then None
(and/or Warning if diagnostic warning)
4.2.2.5 Ready State

Entering the Ready state starts input channel scanning. All active channels are
scanned before the state is completely entered. In this state the module just waits to
be commanded to the Operational state.
Inputs Scanned
Outputs Inactive: 0 V
LEDs None (or Warning if diagnostic warning)
4.2.2.6 Operational State

This is the state for normal operation. After entering the Operational state (from
Ready or OSP), output channels are still unchanged until a valid output value is
written.
Inputs Scanned
Outputs Active
LEDs Run (and Warning if diagnostic warning)
3BSE 020 926R4001 67

4.2.2.7 OSP (Outputs Set as Predefined) State

The OSP state is only used by modules with output channels. If OSP is activated it
is entered from the Operational state in two cases:
• The supervision time-out on PROFIBUS-DP has elapsed.
• The OSP-watchdog expires, no access has been done to the module within
1024 ms (analog) 256 ms (digital).
See OSP-Watchdog on page 69.
Entering the OSP state the module sets its outputs to the predetermined values.
This means “Keep value” or output the configured OSP value. The outputs are kept
unchanged as long as the module stays in the OSP state.
When the PROFIBUS-DP network is operating again the FCI orders the module out
of the OSP state.
After re-entering the Operational state, the outputs are still unchanged until valid
values are written.
Inputs Not applicable
Outputs According to configuration (keep value or OSP value)
LEDs Run, OSP (and Warning if diagnostic warning)
4.2.2.8 Error State

This the state that will be entered if a fault is detected.
Inputs Not scanned
Outputs Inactive (0 V)
LEDs Fault
4.2.2.9 Configuration, Parameters

Configuring an I/O module is equal to writing the parameters to it.
The parameters for a module can mainly be divided into configuration parameters
and non-volatile parameters.
68 3BSE 020 926R4001

4.2.2.10 Loading Parameters

At start-up, the configuration parameters are loaded by the FCI in the
NotConfigured state. When valid configuration parameters are written to the
module, it will change from the Not Configured state to the Ready state.
After entering the Ready state the module may be set to Operational.
The parameters do not need to be remembered on the modules after a reset of the
module since they are saved in the FCI.
4.2.2.11 Loading Invalid Parameters

If parameters that are in some way invalid are sent to a module, this is indicated
with a warning in the module status and by a diagnostic message. If channel
parameters are invalid an error on the channel is indicated.
4.2.2.12 Non-volatile Parameters

Each channel may, apart from the configuration parameters, also have non-volatile
parameters that are stored on the module and written during production and are not
changed by a running system.
4.2.2.13 OSP-Watchdog
The OSP-watchdog is a watchdog timer that all I/O modules with output channels
have. It supervises the communication to discover if the traffic on the ModuleBus is
interrupted. The OSP-watchdog is refreshed when the module is accessed. If this is
not done within the time limit the watchdog will force the module to the OSP state
(see Module States on page 66).
The OSP-watchdog is also activated when the PROFIBUS-DP watchdog has
elapsed. The supervision time for PROFIBUS-DP is defined in the PROFIBUS
configuration tool.
The watchdog on PROFIBUS must be enable to get the OSP function to work on
AO and DO modules at communication error on PROFIBUS.
The watchdog time-out should be set to at least four times the PROFIBUS’s cycle
time.
3BSE 020 926R4001 69

70 3BSE 020 926R4001

Section 5 Maintenance
5.1 Preventive Maintenance

Please see the S800 I/O General Information and Installation manual.
5.2 Hardware Indicators

5.2.1 CI801 FCI Module LEDs
The CI801 FCI has indicators for FAULT, RUN, POWER OK, PROFIBUS-DP
communication traffic. For color and functions see Table 5-3 and the for the
location, see Figure 5-3.
Table 5-1 Standard LEDs on CI840 FCI Module
LED Marking Color Description

F (Fault) Red Fault in the module (1)
R (Run) Green Operational state
P (Power ok) Green Internal power OK
T (Traffic) Yellow Receive transmit data on PROFIBUS
(1) The F-LED will switch on at power up, restart of the module or when the module goes to Error
state. At start up the module will do a self test, if the self test has gone OK the module will switch
off the F-LED.
3BSE 020 926R4001 71

CI801 FCI Module LEDs Section 5 Maintenance
LED Status
Indicators
Figure 5-1 CI801 FCI with Status LEDs Location
72 3BSE 020 926R4001

Section 5 Maintenance CI830 FCI Module LEDs

The CI830 FCI has indicators for FAULT, RUN, POWER OK, two for
PROFIBUS-DP communication and two for optical ModuleBus communications.
For color and functions see Table 5-2 and the for the location see Figure 5-2.
Table 5-2 Standard LEDs on CI830 FCI Module with TB810/TB811

RX (Receive) Yellow Receive data on PROFIBUS-DP
TX (Transmit) Yellow Transmit data on PROFIBUS-DP
Tx (TB810/TB811) Yellow Transmit data on the optical ModuleBus
Rx (TB810/TB811) Yellow Receive data on the optical ModuleBus
off the F-LED.
3BSE 020 926R4001 73

F R
P
RX TX
PROFIBUS
LED Status
SERVICE Indicators
STN. ADDR.
4 56
3 7 x 10
2 8
109
4 56
3 7 x1
2 8
CI830 109
SWX.X/Y TB810/TB811
PROFIBUS Tx Rx
L+
L- Tx
SA
SB Rx
Figure 5-2 CI830 FCI with TB810/TB811 Status LEDs Location
74 3BSE 020 926R4001

Section 5 Maintenance CI840 FCI Module LEDs

The CI840 FCI has indicators for FAULT, RUN, POWER OK, PROFIBUS-DP
communication Rx/Tx and two for redundant configurations PRIMARY and
DUAL. For color and functions see Table 5-3 and the for the location,
see Figure 5-3.
Table 5-3 Standard LEDs on CI840 FCI Module

Rx/Tx (Traffic) Yellow Receive transmit data on PROFIBUS
PRIM (Primary) Yellow Working as Primary
DUAL Yellow Working with a partner
off the F-LED.
3BSE 020 926R4001 75

F F
R R
P P
Rx/Tx Rx/Tx
PRIM PRIM
DUAL DUAL
LED Status
Indicators
CI840 CI840
Figure 5-3 CI840 FCI with Status LEDs Location
76 3BSE 020 926R4001

Section 5 Maintenance Error Messages
5.3 Error Messages

Please see the relevant PROFIBUS Master documentation.
5.4 Fault Finding and User Repair

5.4.1 Communication Module Replacement
5.4.1.1 General
Communications modules CI801, CI830 and TB820 can not be exchanged on-line.
Communications modules CI840 and TB840 can be exchanged on-line.
It is important to understand the consequences of a module exchange and how it
affects the process.
• Replacement of a communication module type CI801 and CI830 affects all
channels on all the modules in an I/O station. The station will loose power.
• Replacement of a communication module type CI840 in a redundant
configuration has no affects on channels in an I/O station.
• Replacement of an optical port type TB810/TB811/TB842 affects all channels
on all the modules in all clusters except cluster 0. The communication will be
broken to all clusters except for cluster 0.
• Replacement of an optical modem type TB820, or TB840 in a single
configuration, connected via a simplex optical cable, affects all channels on all
the modules in all clusters except cluster 0. The communication will be broken
to all clusters except for cluster 0. The cluster where the TB820 should be
replaced will be power less.
• Replacement of an optical modem type TB820 or TB840, in a single
configuration, connected via a duplex optical cable, affects all channels on all
the modules in all clusters after and including the cluster where the replaced
TB820 or TB840 is located. The communication will be broken to all clusters
after where the replaced TB820 or TB840 is located. The cluster where TB820
or TB840 should be replaced will be power less.
3BSE 020 926R4001 77

Communication Module Replacement Section 5 Maintenance
• Replacement of a communication module type TB840 in a redundant

configuration has no affects on channels in an I/O station.
The following headings include general instructions for replacement of modules and
aspects on the handling of individual modules are presented in Table 5-4.
5.4.1.2 Practical Execution

Replace faulty or suspect communication modules in the following way:
For CI840, only perform the steps 1, 2, 3, 8, 11 and 12.
1. Read the S800 I/O General Information and Installation manual.
2. Special restrictions apply to each module type. See descriptions in Table 5-4
for useful information on individual module types.
3. Check that the new module can replace the old for CI801/CI830/CI840, also
check the software version. If the wrong software version is found, then load
new software; see Backup/Restore Procedures on page 83
4. Disconnect the power supply/supplies from the module.
5. Disconnect the PROFIBUS-DP and ModuleBus from the module.
6. Extract the module.
7. Set the current Station address or Cluster address on the new module
8. Insert the new module carefully.
9. Connect the PROFIBUS-DP and ModuleBus to the module.
10. Connect the power supply/supplies to the module.
11. Store extracted modules in protective envelopes.
12. Modules are initialized automatically by the system and it will takes
approximately 60 seconds for a CI801/CI830/CI840 to start up.
5.4.1.3 Additional Aspects on Individual S800 Communications Modules

Table 5-4 lists S800 I/O modules. Descriptions of these types are referred
individually in the table below.
78 3BSE 020 926R4001

Section 5 Maintenance Communication Module Replacement
Table 5-4 Replacement Aspects of S800 I/O Modules
Module Type - Settings Comments

Switch setting for PROFIBUS-DP Can not be replaced with power applied.
address Needs room to the left in order to be removed.
In normal operation mode, before a CI801 is
replaced, the supply to the S800 I/O is to be
switched off. Power connections can be removed
by pulling the header terminals out of the unit.
Optical ModuleBus Port TB842 can not be removed
with power applied.
If a TB842 connected to a CI801 shall be changed
CI801 in a running system, TB806 has to be disconnected
Station Address
FCI Switches from the FCI first.
The fuse for Modulebus 24 V can be changed if the
top cover of the module is removed. Fuse type, see
CI801 Technical Data.
Fieldbus connections can be removed by pulling
the D-way connector out of the unit.
If the last CI801 on a PROFIBUS segment
supplies an active termination in the cable
connector, disconnection of the power
supply or the PROFIBUS cable to CI801
can not be done without disrupting the bus.
3BSE 020 926R4001 79

Communication Module Replacement Section 5 Maintenance
Table 5-4 Replacement Aspects of S800 I/O Modules
Module Type - Settings Comments

Switch setting for PROFIBUS-DP Can not be replaced with power applied.
address Needs room to the left in order to be removed.
In normal operation mode, before a CI830 is
F R
replaced, the supply to the S800 I/O is to be
P
RX
PROFIBUS
TX
switched off. Power connections can be removed

by pulling the header terminals out of the unit.
CI830 Optical ModuleBus Port TB810/TB811 can not be
FCI
SERVICE STN. ADDR.
3
2
4 56
1 0 9
7 x 10
8 Station Address
removed with power applied.
4 56
Switches
Fieldbus connections can be removed by pulling
3 7
x1
2 8
CI830 1 0 9
the D-way connector out of the unit.

PROFIBUS Tx Rx
L+
L- Tx
SA
SB Rx
CI840/TB840: Can be replaced with power applied.
In redundancy applications one CI840/TB840 can
be replaced without any affects on channel in an
I/O station.
If a TB842 connected to a TU846/TU847 shall be
CI840/ changed in a running system, TB806/TB846 has to
TB840 Cluster Address be disconnected from TU846/TU847 first.
Switches
TU846/ TU846/TU847: Needs room to the left in order to be
TU847 removed. Can not be replaced with power applied.
80 3BSE 020 926R4001

Section 5 Maintenance Application Memory Reset
5.4.2 Application Memory Reset

A CI830 can keep an application program in memory for a long time even with the
power supply disconnected. To avoid a problem with an FCI that may have an “old
application” program, the application memory should be cleared. To clear the
application memory in a CI830:
1. Set the address switches to 99.
2. Take away the power supply for a short moment.
3. Apply power and let the FCI restart -- waiting 45 seconds.
Now the application memory is cleared.
4. Set the address switches to the desired station address.
5. Take away the power supply for a short moment.
6. Apply power and let the FCI restart -- waiting 45 seconds.
Now the FCI is cleared and ready for application programming.
5.4.3 CI801 Firmware version

Firmware version is possible to read from the service port (Profibus connection) at
startup.
Do like this:
• Connect a PC to the service port of the CI801 via the service adapter (FS801
and TK802) and cable TK812, see Figure 5-4.
• Start a terminal program in the PC e.g. Hyperterminal.
• Set the communication parameters to 9600 bps, 8 bits word length, no parity,
1 bit stop.
• Set the station address to 0.
• Disconnect power to the CI801 and connect again.
• When the CI801 has started up to operational state it will print out a text string
on the terminal containing version name and number, e.g. CI801 SW 1.0/0.
3BSE 020 926R4001 81

CI840 Firmware version Section 5 Maintenance
5.4.4 CI840 Firmware version

From CI840 firmware version 3.0/0 and onwards it will be possible to read its
firmware version from the service port at startup.
Do like this:
• Connect a PC to the service port of the CI840 via a serial cable (i.e. TK812).
• Start a terminal program in the PC e.g. Hyperterminal.
• Set the communication parameters to 9600 bps, 8 bits word length, no parity,
1 bit stop.
• Disconnect power to the CI840 and connect again.
• When the CI840 has started up to operational state it will print out a text string
on the terminal containing version name and number, e.g. CI840 SW 3.0/0.
82 3BSE 020 926R4001

Section 5 Maintenance Backup/Restore Procedures
5.5 Backup/Restore Procedures

5.5.1 Load the CI801 Software Upgrade
Hardware
PC with WINDOWS NT 4 or 2000.
Service adapter (FS801 + cable TK802) 3BSE038407R1
Connection cable TK212 3BSC630167R2
5.5.1.1 Connection
Connect your PC and the CI801, using a TK212 cable and the service adapter
(FS801+TK802) between the service port (Profibus connection) on CI801 and the
COM1 or COM2 on the PC. Set the station address on CI801 to 0.
PC
CI801
TK212
TK802
FS801
Power Supply
PROFIBUS 24 V
Figure 5-4 CI801 Connection
3BSE 020 926R4001 83

Load the CI801 Software Upgrade Section 5 Maintenance
5.5.1.2 Loading the BASE Software, single FCI

1. Run the program “loader32.exe”
2. Press the button “Next”
3. Choose the setting “User defined: Select COM-Port and speed manually”
5. Select COM-Port to use, and type in the path to the image-file
6. Check the box “Disable optimization of speed (Fix to 9600 BD)” and uncheck
the remaining check boxes
7. Press the button “Download”
8. Loading (takes approx. 15 minutes)
9. Set back the station address to used address.
10. Switch off and then on the power supply to the CI801 and it will start up.
5.5.1.3 What to do in Case of Problems?

Cable was disconnected during download or the power went down.
Solution
Restart CI801 by switching power OFF and ON again.
Repeat the process described above.
84 3BSE 020 926R4001

Section 5 Maintenance Load the CI830 Software Upgrade

Hardware
Connection cable TK527 (3BSC950004R1)
It is assumed that the PC communication port is COM1: and the diskette drive is A.
5.5.2.1 Reset of the CI830 Application Memory

See Application Memory Reset on page 81.
5.5.2.2 Connection
Connect your PC and the CI830, using a TK527 (3BSC950004R1) cable between the
RS232 service port on the CI830 and the COM1 or COM2 on the PC.
5.5.2.3 Loading the BASE Software

• Run the program “loader32.exe”
• Press the button “Next”
• Choose the setting “User defined: Select COM-Port and speed manually”
• Press the button “Next”
• Select COM-Port to use, and type in the path to the image-file
• Check the box “Disable optimization of speed (Fix to 9600 BD)” and uncheck
• Press the button “Download”
• Loading (takes approx. 5 minutes)
3BSE 020 926R4001 85


Solution
Put the largest label on the back of the CI830 and the smaller one on the front of
CI830 according to Figure 5-5.
F R
P
RX Tx
PROFIBUS
STN. ADDR.
4 56
3 7 x 10
2 8
109
5
4 6
3 7x 1
2 8
CI830 109
Label SW*1.1/0 PROFIBUS
L+
L-
SA
SB
Figure 5-5 CI830 Software Label Location
86 3BSE 020 926R4001


Hardware
Connection cable TK212 3BSC630167R2.
It is assumed that the PC communication port is COM1: and the diskette drive is A.
5.5.3.1 Connection
Connect your PC and the CI840 (TU846/TU847), using a TK212 (3BSC630167R2)
cable between the RS232 service port A or B on the TU846/TU847 (CI840) and the
COM1 or COM2 on the PC.
5.5.3.2 Loading the BASE Software, single FCI

1. Run the program “loader32.exe”
3. Choose the setting “User defined: Select COM-Port and speed manually”
5. Select COM-Port to use, and type in the path to the image-file
6. Check the box “Disable optimization of speed (Fix to 9600 BD)” and uncheck
7. Press the button “Download”
8. Loading (takes approx. 15 minutes). When down load is finished the CI840
will start up automatically.
5.5.3.3 Loading the BASE Software in the Backup FCI when the Primary is
Running
1. Follow the instructions according to Loading the BASE Software, single FCI
on page 87 until step 7.
2. The red fault LED is lit.
3BSE 020 926R4001 87

3. Disconnect the power supply from the backup FCI by unlocking the screw and
locking it again.
4. Continue the procedure from step 7 in Loading the BASE Software, single FCI
on page 87 without any waiting.
5. If the downloading doesn’t start, step 3 and 4 have to be repeated.
88 3BSE 020 926R4001


Solution
F F
R R
P P
Rx/Tx Rx/Tx
PRIM PRIM
DUAL DUAL
Position A Position B
CI840 CI840
Service
port
Figure 5-6 CI840 and TU847
3BSE 020 926R4001 89

90 3BSE 020 926R4001

Appendix A Specifications
A.1 CI801 Fieldbus Communications Interface (FCI)

A.1.1 Features
• PROFIBUS-DPV1 fieldbus interface.
• Supervisory functions of I/O ModuleBus
• Isolated power supply to I/O modules
• OSP handling and configuration
• Input power fused
• Hot Configuration In Run
• HART pass-trough
A.1.2 Description
The CI801 Fieldbus Communications
Interface (FCI) is an intelligent
communication interface between a
Controller via the PROFIBUS-DPV1 fieldbus
and the S800 I/O modules via the
ModuleBus.
CI801 contains one PROFIBUS-DPV1 interface, electrical ModuleBus interfaces,
LED indicators and a service port.
The Profibus connector is also used for service.
Two rotary switches for station address 0-99 settings (0 is used for service).
3BSE 020 926R4001 91

Description Appendix A Specifications
CI801 has isolated power converters that generates internal power for CI801 and
current limited +5 V supply for electrical ModuleBuses.
Besides +5 V CI801 also distribute a fused 24 V for the ModuleBus.
The module is DIN-rail mounted and grounded to the DIN-rail. The module
detachable screw terminals for power supply D-way terminals for PROFIBUS-
DPV1, one connector for the Optical ModuleBus Port TB842, mounted on TB806,
and one electrical ModuleBus.
92 3BSE 020 926R4001

Appendix A Specifications Description
A.1.3 Technical Data

Table A-1 CI801 FCI Specification
Item Description
Microprocessor (CPU) Motorola MCF5307 with a speed of
64 MHz
Flash PROM 1 Mbyte
Fast RAM 8 Mbyte
Power Input 24 V d.c. (19.2 - 30)
Power Input Fuse 2 AF
Power Consumption at 24 V d.c. 140 mA
Power Dissipation 5.4 W
Maximum Ambient Temperature 55°C (131°F) horizontal mounted
40°C (104°F) vertical mounted
PROFIBUS-DPV1 (D-sub 9-pole female Opto-isolated (RS-485);
socket), also used as Service Port 12 Mbit/s maximum
ModuleBus Maximum of 12 I/O modules
Power Output - ModuleBus 24 V max. = 1.5 A fused(1)
5 V max. = 1.5 A current limited
Safety classification Class I according to IEC 536; (earth
protected)
Protection rating IP20 according to IEC 529, (IEC 144)
Rated insulation voltage 50 V
Dielectric test voltage 500 V a.c.
Width 86.1 mm (3.39”)
Depth 58.5 mm (2.30”)
3BSE 020 926R4001 93

Table A-1 CI801 FCI Specification (Continued)
Item Description
Height 110 mm (4.33”)
Weight 0.3 kg (0.66 lb.)
(1) Fuse type: Subminiature fuse 3.15 A
- LT-5 Fast-Acting 622 series according to Littel fuse
- TR5-F Fuse-link No. 370 according to Wickmann
- MSF 250 according to Schurter
A.1.4 Dimensions
Figure A-1 CI801 FCI Dimensions
94 3BSE 020 926R4001

Appendix A Specifications Description
A.1.5 Connections
Table A-2 Power Supply Connections (XI)

Table A-3 FCI PROFIBUS Connections (X2), Also Used as Service Port

2 NC Not used
3 RxD/TxD-P Receive data/transmit data positive
5 DGND Data ground
6 VP Supply of termination resistance (5V)
7 NC Not used
8 RxD/TxD-N Receive data/transmit data negative
3BSE 020 926R4001 95

A.1.6 Block Diagram CI801
TB806 CI801
Electrical
TB842 Modulebus
Profibus
Station
address
Power
supply
Figure A-2 Block Diagram CI801
96 3BSE 020 926R4001

Appendix A Specifications CI830 Fieldbus Communications Interface (FCI)

A.2.1 Features
• PROFIBUS-DP fieldbus interface. F R
P
RX TX
• Supervisory functions of I/O
ModuleBus
• OSP handling and configuration
• DIN rail mounting
A.2.2 Description SERVICE

STN. ADDR.
The CI830 Fieldbus Communications 4 56
3 7
2 8 x 10
Interface (FCI) is an intelligent 109
4 56
communication interface between a 3
2
7
8x 1
CI830 109
Controller via the PROFIBUS-DP fieldbus
and the S800 I/O modules via the PROFIBUS TxRx
ModuleBus. X3
L+
Tx
CI830 has four basic parts: Module L-
SA
termination board, power supply board, SB Rx
processor board and the optical port (see
block diagram).
X1
The power supply board has an isolated
power converter that generates a short X2
circuit proof +5 V supply for the CI830 and
I/O modules. It also contains opto-isolated RS232 drivers/receivers for the service
port.
The Processor board contains the CPU, RAM, Flash PROM, ModuleBus interfaces,
PROFIBUS-DP protocol chip, LED indicators and two rotary switches for the units
PROFIBUS station address.
The termination board is a unit where most of the connections to the outside takes
place. It is grounded to the DIN-rail through a metallic spring connector. The board
carries screw terminals for power supply and redundant power supply monitoring,
3BSE 020 926R4001 97

CI830 Fieldbus Communications Interface (FCI) Appendix A Specifications
D-way terminal for PROFIBUS-DP, connector for the service port, connector for
the Optical ModuleBus Port TB810/TB811 and the electrical ModuleBus.
98 3BSE 020 926R4001


Item Description
Microprocessor (CPU) Motorola MC68340 running at 8 bit
mode with a speed of 16 MHz
Flash PROM 512 kbyte
Fast RAM 256 kbyte (backed-up)
Power Input 24 V d.c. (19.2 - 30)
Maximum Ambient Temperature 55°C (131°F)
Power Supply Monitoring Inputs Max. input voltage: 30 V
Min. input voltage for high level: 15 V
Max. input voltage for low level: 8 V
Service Port (D-sub 9-pole female Opto-isolated (RS-232);
socket) 19.2 Kbaud/s maximum
PROFIBUS-DP (D-sub 9-pole female Opto-isolated (RS-485);
socket) 12 Mbit/s maximum
Power Output - ModuleBus 24 V max. = 1.4 A
5 V max. = 1.5 A
Current limited
protected)
3BSE 020 926R4001 99

Dimensions Appendix A Specifications
Item Description
Width 84 mm (3.3”)
Depth 122 mm (4.8”)
Height 170 mm (6.7”) including latch
A.2.4 Dimensions
Figure A-3 CI830 FCI Dimensions
100 3BSE 020 926R4001

Appendix A Specifications Dimensions
A.2.5 Connections
Table A-5 Power Supply Connections (XI)

2 SA Redundant Power Supply “A”
Monitoring Input
1 SB Redundant Power Supply “B”
Monitoring Input
Table A-6 Service Port (X3)

1
2 TD Transmit Data channel B
3 RD Receive Data channel B
4
5 SG Signal Ground
6
7 RDA Receive Data channel A (for
debugging only)
8 TDA Transmit Data channel A (for
debugging only)
9
3BSE 020 926R4001 101

Dimensions Appendix A Specifications
Table A-7 FCI PROFIBUS Connections (X2)

2 - Not used
4 - Not used
5 DGND Data ground
6 VP Supply voltage for the terminating
resistors
7 - Not used
8 RxD/TxD-N Receive/Transmit data - minus
9 - Not used
102 3BSE 020 926R4001

Appendix A Specifications Dimensions
A.2.6 Block Diagram CI830
E
Fiber Optical RX
Modulebus Module O
E TX X2
O
SHIELD 1
VP 6
DGND 5
PROFIBUS Connector
GLUE DSUB9
STN. RxD/TxD-P 3
ADDR SPC4 RS-485
8
RxD/TxD-N
MC68340
DDCC+
FLASH
RAM Reset logic,

Rx
Tx +5 V Supervision
RS-485
+5 V +5 V
P(owok) RS-485
DIN-rail
R(un) X9
0V 0V POWOK
F(ault) D+,D-
CLK+,CLK-
POS(9:0)
+5 V
Electrical Modulebus
+5V Connector
+5 V +5 V 0V
0V24
0V +24V
0V 0V
X3
Service Port
Connector
BATOK
+5 V
X1
0V SB 1
IRQ7-N
L- 3
DC DC
DC DC
Current
Limit
SA 2
L+ 4
3BSE 020 926R4001 103


A.3.1 Features
• PROFIBUS-DPV1 fieldbus interface.
F
• Supervisory functions of I/O ModuleBus R
P
Rx/Tx
• OSP handling and configuration PRIM
• Input power fused DUAL
• Hot Configuration In Run

• HART pass-through
A.3.2 Description
The CI840 Fieldbus Communications Interface
(FCI) is an intelligent communication interface
between a Controller via the PROFIBUS-
DPV1 fieldbus and the S800 I/O modules via
the ModuleBus.
CI840 is designed to be used in redundant
applications.
CI840 contains one PROFIBUS-DPV1
interface, two electrical ModuleBus interfaces, CI840
LED indicators and a opto-isolated RS232
service port.
CI840 has isolated power converters that generates internal power for CI840 and
current limited +5 V supply for two electrical ModuleBuses.
Besides +5 V CI840 also distribute a current limited 24 V for the two ModuleBuses.
CI840 must be mounted on a Module Termination Unit TU846 or TU847. With
CI840 mounted on a TU847, only one electrical ModuleBus is connected. When
mounted on a TU846, two electrical ModuleBuses are connected.
104 3BSE 020 926R4001

The Module Termination unit is DIN-rail mounted and grounded to the DIN-rail.
The Module Termination Unit TU847 carries screw terminals for power supply and
redundant power supply monitoring, two D-way terminals for PROFIBUS-DPV1,
two connectors for the service ports, one connector for the Optical ModuleBus Port
TB842, mounted on TB806, and one electrical ModuleBus.
The Module Termination Unit TU846 carries screw terminals for power supply and
redundant power supply monitoring, two D-way terminals for PROFIBUS-DPV1,
two connectors for the service ports, two connectors for the Optical ModuleBus Port
TB842, mounted on TB846, and two electrical ModuleBuses.
3BSE 020 926R4001 105

F F
R R
P P
Rx/Tx Rx/Tx
PRIM PRIM
DUAL DUAL
CI840 CI840
Figure A-4 CI840 and TU847
106 3BSE 020 926R4001


Item Description
Microprocessor (CPU) Motorola MCF5307 with a speed of
64 MHz
Flash PROM 1 Mbyte
Fast RAM 8 Mbyte
Power Input 24 V d.c. (19.2 - 30)
Power Input Fuse 2 AF
Maximum Ambient Temperature 55°C (131°F) horizontal mounted
40°C (104°F) vertical mounted
Power Supply Monitoring Inputs Max. input voltage: 30 V
Min. input voltage for high level: 15 V
Max. input voltage for low level: 8 V
Service Port (RJ 45 connector on Opto-isolated (RS-232);
TU847) 19.2 Kbaud/s maximum
PROFIBUS-DPV1 (D-sub 9-pole female Opto-isolated (RS-485);
socket) 12 Mbit/s maximum
Power Output - ModuleBus 24 V max. = 1.4 A
5 V max. = 1.5 A
Current limited
Switch over time at failure in a Typical <100 ms
redundant CI840 configuration Maximum 150 ms
MTU Keying code AA
3BSE 020 926R4001 107

Item Description
protected)
Width 54 mm (2.13”)
Depth 96 mm (3.78”)
Height 119 mm (4.69”)
A.3.4 Connections
See Connections on page 120.
108 3BSE 020 926R4001

A.3.5 Block Diagram CI840, single ModuleBus
Figure A-5 Block Diagram CI840, single ModuleBus
3BSE 020 926R4001 109

Block Diagram CI840, dual ModuleBus Appendix A Specifications
A.3.6 Block Diagram CI840, dual ModuleBus
TB846 Optical
TU846
TB842 module bus CI840 Electrical
+5V_B Modulebus A
A
MODULEBUS A
TXA
RXA X3A
POWOKA
POWA +5V_A
+24V_A
TXB Electrical POS6-0
RXB Modulebus B
POWB
POWOKB
+5V_B
+24V_B
X2A
Profibus A
RTS
+5V_P
0V_P
Service A
Stn.address
+5V +5V Power

supply
SHUTDB
SHUTDA
SYNC
FCL1
FCL2
MTU_SEL
A/B-N
BLOCK L+
CI840
TB842
MODULEBUS B
TXA
B RXA X3B
POWOKA
POW_A +5V_A
+24V_A
TXB
RXB
POW_B
POWOKB
+5V_A +5V_B POS6-0
+24V_B
X2B
RTS
+5V_P
0V_P
+5V +5V
5V_A
5V_B
A/B-N
MTU_SEL
BLOCK L+
POWER
SERV. A
SERV. B
PB A
PB B
0V
STATION
ADDRESS
X1 X4A X4B X5A X5B
Figure A-6 Block Diagram CI840, dual ModuleBus
110 3BSE 020 926R4001

Appendix A Specifications TU846 Redundant MTU for CI840, dual ModuleBus
A.4 TU846 Redundant MTU for CI840, dual ModuleBus

A.4.1 Features
• Power supply connection
• Two PROFIBUS connections
• Two service tool connections
• Two rotary switch for station
address setting
• Connection for two ModuleBuses
• Connector for ModuleBus Optical
Port
• Mechanical keying prevents
insertion of the wrong module
type
• Latching device to DIN rail for
locking and grounding
• DIN rail mounted.
A.4.2 Description
The TU846 is a module termination unit (MTU) for redundant configuration of the
field communication interface CI840 and redundant I/O.
The MTU is a passive unit having connections for power supply, two electrical
ModuleBuses, two CI840 and two rotary switches for station address (0 to 99)
settings.
A ModuleBus Optical Port TB842 can be connected to TU846 via TB846.
Four mechanical keys, two for each position, are used to configured the MTU for
the right types of modules. Each key has six positions, which gives a total number of
36 different configurations. The configurations can be changed with a screwdriver.
3BSE 020 926R4001 111

TU846 Redundant MTU for CI840, dual ModuleBus Appendix A Specifications
The MTU can be mounted on a standard DIN rail. It has a mechanical latch that
locks the MTU to the DIN rail. The latch can be locked/unlocked with a
screwdriver.
The MTU has two BLOCK signals, one for each module position, that keeps the
modules in its init state until it is locked in its position.

Table A-9 TU846 Redundant MTU for CI840
Item Value
Power input 24 V d.c. (19.2 - 30 V)
PROFIBUS connection DSUB9 connector
Service ports RJ45 connector
ModuleBus current distribution
Maximum 5 V 1.5 A
Maximum 24 V 1.5 A
Mechanical keys (2) 36 different combinations
Safety Classification Class I according to IEC 536; (earth
protected)
Protection Rating IP20 according to IEC 529, (IEC 144)
Width 124 mm (4.88”)
Depth 47 mm (1.85”)
Weight 0.5 kg (1.1 lbs.)
112 3BSE 020 926R4001

A.4.4 Dimensions
Figure A-7 Dimensions TU846
3BSE 020 926R4001 113

A.4.5 Connections
Table A-10 TU846 Power Supply Connections
Designation Description
L+ +24 V d.c. Supply In
L- 0 V d.c. Supply In
SA Redundant Power Supply “A” Monitoring Input
SB Redundant Power Supply “B” Monitoring Input
Table A-11 PROFIBUS Connector Pin-out

2 NC Not used
5 DGND Data ground
7 NC Not used
Table A-12 Service Port Connector Pin-out

1 NC Not used
2 NC Not used
3 Tx Transmitted data
114 3BSE 020 926R4001

Table A-12 Service Port Connector Pin-out (Continued)

4 GND Signal ground
5 GND Signal ground
6 Rx Receive data
7 NC Not used
8 NC Not used
3BSE 020 926R4001 115

A.4.6 Block Diagram TU846
TB846 Optical
TU846
TB842 module bus CI840 Electrical
+5V_B Modulebus A
A
MODULEBUS A
TXA
RXA X3A
POWOKA
POWA +5V_A
+24V_A
TXB Electrical POS6-0
RXB Modulebus B
POWB
POWOKB
+5V_B
+24V_B
X2A
Profibus A
RTS
+5V_P
0V_P
Service A
Stn.address
+5V +5V Power

supply
SHUTDB
SHUTDA
SYNC
FCL1
FCL2
MTU_SEL
A/B-N
BLOCK L+
CI840
TB842
MODULEBUS B
TXA
B RXA X3B
POWOKA
POW_A +5V_A
+24V_A
TXB
RXB
POW_B
POWOKB
+5V_A +5V_B POS6-0
+24V_B
X2B
RTS
+5V_P
0V_P
+5V +5V
5V_A
5V_B
A/B-N
MTU_SEL
BLOCK L+
POWER
SERV. A
SERV. B
PB A
PB B
0V
STATION
ADDRESS
X1 X4A X4B X5A X5B
Figure A-8 Block Diagram TU846
116 3BSE 020 926R4001

Appendix A Specifications TU847 Redundant MTU for CI840, single ModuleBus
A.5 TU847 Redundant MTU for CI840, single ModuleBus

A.5.1 Features
• Power supply connection
• Two PROFIBUS connections
• Two service tool connections
• Two rotary switch for station
address setting
• ModuleBus connections
• Connector for ModuleBus Optical
Port
• Mechanical keying prevents
insertion of the wrong module
type
• Latching device to DIN rail for
locking and grounding
• DIN rail mounted.
A.5.2 Description
The TU847 is a module termination unit (MTU) for redundant configuration of the
field communication interface CI840.
The MTU is a passive unit having connections for power supply, electrical
ModuleBus, two CI840 and two rotary switches for station address (0 to 99)
settings.
A ModuleBus Optical Port TB842 can be connected to TU847 via TB806.
Four mechanical keys, two for each position, are used to configured the MTU for
the right types of modules. Each key has six positions, which gives a total number of
36 different configurations. The configurations can be changed with a screwdriver.
3BSE 020 926R4001 117

TU847 Redundant MTU for CI840, single ModuleBus Appendix A Specifications
The MTU can be mounted on a standard DIN rail. It has a mechanical latch that
locks the MTU to the DIN rail. The latch can be locked/unlocked with a
screwdriver.
The MTU has two BLOCK signals, one for each module position, that keeps the
modules in its init state until it is locked in its position.

Table A-13 TB847 Redundant MTU for CI840
Item Value
Power input 24 V d.c. (19.2 - 30 V)
PROFIBUS connection DSUB9 connector
Service ports RJ45 connector
ModuleBus current distribution
Maximum 5 V 1.5 A
Maximum 24 V 1.5 A
Mechanical keys (2) 36 different combinations
Safety Classification Class I according to IEC 536; (earth
protected)
Protection Rating IP20 according to IEC 529, (IEC 144)
Width 124 mm (4.88”)
Depth 47 mm (1.85”)
Weight 0.5 kg (1.1 lbs.)
118 3BSE 020 926R4001

A.5.4 Dimensions
Figure A-9 Dimensions TU847
3BSE 020 926R4001 119

A.5.5 Connections
Table A-14 TU847 Power Supply Connections
Designation Description
L+ +24 V d.c. Supply In
L- 0 V d.c. Supply In
SA Redundant Power Supply “A” Monitoring Input
SB Redundant Power Supply “B” Monitoring Input
Table A-15 PROFIBUS Connector Pin-out

2 NC Not used
5 DGND Data ground
7 NC Not used
Table A-16 Service Port Connector Pin-out

1 NC Not used
2 NC Not used
3 Tx Transmitted data
120 3BSE 020 926R4001

Table A-16 Service Port Connector Pin-out (Continued)

4 GND Signal ground
5 GND Signal ground
6 Rx Receive data
7 NC Not used
8 NC Not used
3BSE 020 926R4001 121

A.5.6 Block Diagram TU847
Figure A-10 Block Diagram TU847
122 3BSE 020 926R4001

INDEX
C P
CI830 18, 20, 23, 79 to 80, 83, 85, 87 Parameters
Connections Loading 69
Power supply 34, 38, 42 Loading invalid 69
PROFIBUS-DP 32, 35, 40 Non-volatile 69
PROFIBUS-DP 14, 18, 20, 23, 61
D I/O module functionality 65
Data scanning principles 64
R
E Ready state 67
Error state 68
S
F State
FCI 13, 18, 20, 23, 61, 79 to 80, 91, 97, 104 Error 68
FCI module 18, 20, 23 Init 67
Fieldbus communications interface 91, 97, 104 Not configured 67
Operational 67
I OSP (Outputs Set as Predefined) 68
I/O module functionality Ready 67
PROFIBUS-DP 65 Station address selector
I/O station 13 PROFIBUS-DP 31, 35, 39
Init state 67
L
LEDs
FCI 71, 73, 75
N
Not configured state 67
O
Operational state 67
OSP 69
OSP state 68
3BSE 020 926R4001 123

Index
124 3BSE 020 926R4001

3BSE 020 926R4001. Printed in Sweden October 2004
Copyright © 2004 by ABB. All Rights Reserved
® Registered Trademark of ABB.
™ Trademark of ABB.
http://www.abb.com/control
Automation Technology Products Automation Technology Products Automation Technology Products

Västerås, Sweden Wickliffe, Ohio, USA Mannheim, Germany
www.abb.com/processautomation www.abb.com/processautomation www.abb.de/processautomation
email: processautomation@se.abb.com email: industrialitsolutions@us.abb.com email: marketing.control-products@de.abb.com

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IndustrialIT

800xA - Control and I/O

Fieldbus Communication Interface

Fieldbus Communication Interface

Copyright © 2003 - 2004 by ABB.

Release: October 2004

Windows Registered trademark of Microsoft Corporation.

Industrial IT Trademark of ABB.

Advant Registered trademark of ABB.

Advant Fieldbus Trademark of ABB.

PROFIBUS Registered trademark of Profibus International (P.I.)

PROFIBUS-DP Registered trademark of Profibus International (P.I.)

HART Registered trademark of HART Communication Foundation.

About This Book

Section 2 - Installation ......................................................................................29

3BSE 020 926R4001 5

3.3 CI840 FCI.................................................................................................................. 39

6 3BSE 020 926R4001

4.2.2.10 Loading Parameters...............................................................69

3BSE 020 926R4001 7

5.5.3.2 Loading the BASE Software, single FCI................................ 87

8 3BSE 020 926R4001

A.4.6 Block Diagram TU846 .............................................................................116

3BSE 020 926R4001 9

10 3BSE 020 926R4001

3BSE 020 926R4001 11

0.2 Use of Warning, Caution, Information, and Tip Icons

Caution icon indicates important information or warning related to the concept

Information icon alerts the reader to pertinent facts and conditions.

12 3BSE 020 926R4001

3BSE 020 926R4001 13

0.4 Applicable Specifications

14 3BSE 020 926R4001

0.5 Related Documentation

3BSE 020 926R4001 15

16 3BSE 020 926R4001

3BSE 020 926R4001 17

1.1 Product Overview

1.1.1 Product Scope

1.1.1.1 CI801 Fieldbus Communications Interface (FCI)

18 3BSE 020 926R4001

3BSE 020 926R4001 19

1.1.1.2 CI830 Fieldbus Communications Interface (FCI)

20 3BSE 020 926R4001

Figure 1-3 CI830 FCI Module

3BSE 020 926R4001 21

Figure 1-4 CI830 FCI Dimensions

22 3BSE 020 926R4001

1.1.1.3 CI840 Fieldbus Communications Interface (FCI)

3BSE 020 926R4001 23

Power Supply Service

24 3BSE 020 926R4001

3BSE 020 926R4001 25

26 3BSE 020 926R4001

Figure 1-7 TU847 Dimensions (Same Dimensions for TU846)

3BSE 020 926R4001 27

28 3BSE 020 926R4001

3BSE 020 926R4001 29

30 3BSE 020 926R4001