ABB CI840 (3BSE022457R1) – PROFIBUS DP-V1 Communications Interface for S800 I/O

The ABB CI840 3BSE022457R1 is a PROFIBUS communications interface designed to present an ABB S800 I/O station as a DP/DP‑V1 device on a standard PROFIBUS network. It’s typically used when you want to keep the flexibility of S800 I/O but connect it to a third‑party PLC or an existing DP master without changing the control layer.

From my experience, it’s a solid fit for brownfield upgrades, line extensions, or anytime you need clean and deterministic I/O mapping over PROFIBUS. You get stable cyclic data exchange and acyclic services for diagnostics, which in many cases cuts maintenance time and speeds up commissioning.

• PROFIBUS DP/DP‑V1 support – Cyclic I/O data plus acyclic parameterization and diagnostics, so you can read device status without halting the process.

• Seamless S800 I/O mapping – Presents connected S800 modules (DI/DO/AI/AO, and HART-capable modules where applicable) as standard DP data to the master.

• GSD-based integration – Standard GSD file workflow with common engineering tools; typically quick to drop into Siemens, ABB, or mixed-vendor DP networks.

• Robust diagnostics – LED indicators and DP‑V1 diagnostics help pinpoint wiring faults, module health, and configuration mismatches faster.

• Industry-proven form factor – Mounts on S800 terminal bases (TB8xx series) for compact DIN-rail installations and clean cabinet layouts.

• 12 Mbit/s bus speeds – Works across standard PROFIBUS baud rates, which simplifies retrofits and mixed-speed segments.

You’ll typically see the CI840 used to expose an S800 I/O station to a PROFIBUS master in:

• Process industries (chemicals, oil & gas, pharma) where robust diagnostics and deterministic I/O updates matter.

• Hybrid manufacturing and utilities—water/wastewater, power auxiliaries—tying ABB I/O into existing DP backbones.

• Retrofits and expansions where a Siemens S7 or other DP master needs access to S800 I/O without changing the control platform.

• Reliability – Stable DP‑V1 stack and proven S800 hardware reduce nuisance faults in harsh panels.

• Compatibility – Works with mainstream DP masters via standard GSD files; no obscure drivers in most cases.

• Lifecycle cost savings – Reuse existing S800 I/O and wiring while integrating with legacy or mixed-vendor systems.

• Serviceability – Clear status LEDs and DP diagnostics shorten troubleshooting during startups and shutdowns.

A maintenance supervisor at a beverage plant told me they swapped an older node for CI840 and were online in under an hour—“the GSD dropped right in, and the alarms made it obvious we had a shield issue on one segment.”

• Cabinet & mounting – Install on TB8xx terminal base, DIN‑rail in a clean, ventilated enclosure. Maintain adequate spacing for airflow.

• Wiring practices – Use PROFIBUS‑compliant cable, proper shielding/grounding, and end-of-line termination. Keep signal and power separated to reduce noise.

• Addressing & configuration – Set the device address per site standards; import the GSD into the master engineering tool and map channels as needed.

• Safety – De-energize before insertion/removal. Verify bus termination and shield continuity, especially in high‑EMI areas.

• Routine care – Periodic inspection of connectors and cable shields; dust cleanup; back up configuration files; apply firmware updates per ABB guidance when recommended.

• Conforms to relevant EMC and safety directives; CE marking.

• Commonly supplied with UL/cUL and RoHS compliance for industrial control equipment.

• Manufactured under ISO 9001 quality systems.

• Manufacturer’s standard warranty applies; extended coverage options are typically available via channel.

If you’re pairing CI840 with specific S800 modules or a particular DP master, I can suggest a tested channel mapping and a sample GSD configuration to shorten your commissioning window.