ABB S800 I/O PROFIBUS DP Slave Communication Interface CS513

Description

Application Scenarios:

In a large water treatment plant, the process is controlled by a central Siemens S7-400 PLC acting as the main controller over a PROFIBUS DP network. However, in a remote pumping station located 500 meters away, there are numerous field instruments (pressure transmitters, valve positioners, motor starters) that need to be monitored and controlled. Running individual cables back to the central PLC is costly and complex. The ABB CS513 3BSE000435R1 (CI871)​ module provides the elegant solution. Installed in an S800 I/O rack at the remote pumping station, it connects local S800 I/O cards (for analog and digital signals) to the field devices. The CI871​ then acts as a slave on the plant-wide PROFIBUS DP network. The master S7-400 PLC can now read all the pump pressures and valve statuses, and send control commands to start/stop motors via this single PROFIBUS cable, as if the I/O were locally attached. This addresses the key pain points of long-distance wiring, cost, and system integration, enabling efficient, distributed control architecture.

Technical Principles and Innovative Values:

The ABB CI871​ is engineered as a protocol translator and data concentrator, bringing flexibility to the otherwise controller-specific S800 I/O system.

Innovation Point 1: Decoupling I/O from the Controller.​ Traditionally, remote I/O is tightly coupled to its parent controller’s brand and backplane. The CI871’s core innovation is that it allows an ABB S800 I/O station—a high-density, reliable I/O platform—to function independently of an ABB controller. By acting as a standard PROFIBUS DP slave, it makes the S800 I/O rack appear as a generic remote I/O station to anyPROFIBUS DP master. This provides exceptional vendor interoperability and allows the best-in-class I/O system to be used in multi-vendor automation environments.

Innovation Point 2: Configuration Flexibility via GSD File.​ The module uses a standard PROFIBUS Generic Station Description (GSD) file. This file, loaded into the master’s configuration tool (e.g., Siemens STEP 7), provides the master with all the necessary information about the CI871’s capabilities and the specific I/O module configuration behind it. This plug-and-play philosophy simplifies engineering, as the master controller automatically understands the data structure (how many input and output bytes are available) without needing low-level driver development.

Innovation Point 3: Diagnostic Gateway.​ The CI871​ provides comprehensive diagnostic data flow in both directions. It reports its own health and PROFIBUS communication status to the master. Crucially, it also relays channel-level diagnostic information from the individual S800 I/O modules (e.g., “wire break on AI channel 3”) over the PROFIBUS network to the master controller. This enables centralized monitoring and predictive maintenance, as the PLC or SCADA system can receive detailed fault information from the remote station, not just a simple “module fault” indication.

Application Cases and Industry Value:

Case Study: Integrating Legacy and New Equipment in a Pharmaceutical Plant

A pharmaceutical facility was retrofitting a new distillation unit controlled by an ABB AC 800M system into an existing plant where the overarching Building Management System (BMS) and some legacy skids were controlled by a Siemens S7-300 PLC over PROFIBUS. The new distillation unit had dozens of local temperature, pressure, and flow signals that needed to be integrated into the plant’s main Siemens-controlled SCADA for centralized monitoring and batch reporting.

Instead of running a separate control network or adding costly gateways at the controller level, the engineers used an S800 I/O station with an ABB CS513 3BSE000435R1 (CI871)​ module locally in the distillation unit panel. All field instruments were wired to standard S800 I/O cards. The CI871​ was then connected to the existing plant-wide PROFIBUS DP network. The Siemens master was configured with the CI871’s GSD file, mapping the S800 I/O points into its process image.

Result:​ The Siemens PLC seamlessly read all distillation process variables and could send basic setpoints or commands. The plant’s central SCADA now had full visibility of the new unit without any modification to its existing Siemens-based architecture. The project lead noted, “The CI871​ module was the perfect bridge. It allowed us to use the optimal I/O system for the new unit while effortlessly integrating it into the legacy plant network. It saved us weeks of software development and hardware costs for a custom interface.” The solution demonstrated flexibility, preserved existing investments, and streamlined integration.

Related Product Combination Solutions:

The ABB CI871​ is the communication head for a distributed S800 I/O station. A complete solution involves:

S800 I/O Baseplate (e.g., TB801. TB811):​ The mounting unit that provides mechanical mounting, internal bus, and power to the CI871​ and other I/O modules.

S800 I/O Modules:​ The actual signal interface cards that the CI871​ serves, such as:

AI810:​ Analog Input module

DI810:​ Digital Input module

DO810:​ Digital Output module

AO810:​ Analog Output module

S800 Power Supply (e.g., SD821. SD822):​ A dedicated power supply unit that provides 24V to the field sensors/actuators and converts it to the 5V/24V needed for the baseplate and modules.

PROFIBUS Connector & Cable:​ Standard PROFIBUS network components (e.g., ABB PROFIBUS connectors, shielded cable) to connect the CI871​ to the network.

PROFIBUS DP Master:​ This could be a:

Siemens S7-300/400/1500 PLC with a DP master port (e.g., CP 342-5).

ABB AC 800M controller with a PROFIBUS master module (e.g., CI854).

Any other automation controller with PROFIBUS DP master capability.

ABB CMT (Configuration and Maintenance Tool):​ The software tool used to configure the S800 I/O station’s hardware layout, which is necessary to generate the correct GSD file for the master.

Installation, Maintenance, and Full-Cycle Support:

Installation of the ABB CI871​ module is straightforward for trained personnel. It snaps into a slot on the left side of an S800 baseplate. The PROFIBUS address is set using the rotary switches on its front. The PROFIBUS network cable is connected to its 9-pin port, ensuring proper termination and shielding. Configuration is a two-step process: first, the S800 station’s hardware (including the CI871​ and all I/O modules) must be defined in ABB’s CMT software to create a valid configuration. Second, the generated GSD file is imported into the PROFIBUS master’s configuration tool, where the I/O data is mapped into the master’s memory.

Maintenance is primarily monitoring-based. The module’s status is indicated by LEDs for power, communication, and errors. Diagnostics are best viewed from the master station’s engineering software. The module is a solid-state device with high reliability. If a fault occurs, replacement is simple: power down, note the PROFIBUS address setting, swap the module, restore the address, and reboot. The configuration is stored in the master, so no reload is needed on the module itself.

We provide full-cycle support for the ABB CS513 3BSE000435R1 (CI871), from confirming its suitability for your network architecture (baud rate, master compatibility) to supplying the genuine module and associated S800 I/O components. Our technical team can assist with GSD file handling, station configuration basics, and troubleshooting communication issues, ensuring a smooth integration of your distributed I/O.

Need to connect ABB S800 I/O to a PROFIBUS DP network?​ Contact us today for the ABB CS513 3BSE000435R1 (CI871)​ module and expert support to implement a robust, distributed I/O solution.