Description

ABB AI843 3BSE028925R1

ABB AI843 3BSE028925R1 is an 8-channel analog input module, whose core positioning is to achieve the accurate acquisition and stable transmission of thermocouple (TC) and millivolt (mV) signals in industrial automation scenarios. It features flexible deployment capability in single-channel or redundant configuration modes, and undertakes the core task of converting weak analog signals generated by on-site physical quantities such as temperature into digital signals recognizable by the control system, while ensuring the reliability of signal acquisition and the stability of transmission. It is a key interface component connecting on-site industrial sensors and upper-level control systems (e.g., ABB Advant 800xA System). This module is widely used in various industrial fields including the power industry, elevator industry, automobile and auto parts manufacturing, feed processing, aluminum smelting, refrigeration industry, iron and steel industry, combustion control systems, non-ferrous metal smelting, glass manufacturing, construction machinery, textile machinery, and water treatment. It can be precisely matched with the ABB S800 I/O distributed control system and a variety of mainstream controllers, providing reliable data support for automated process control and working condition monitoring in various industries.

Relying on modular design, multi-channel differential acquisition technology, and flexible redundant configuration capability, the ABB AI843 3BSE028925R1 module can efficiently adapt to the signal acquisition requirements of different industrial scenarios. While improving the acquisition accuracy and anti-interference capability of weak analog signals, it further enhances the operational reliability of the system through redundant configuration, reduces system downtime caused by module failures, and lowers operation and maintenance costs. It is an important core component in industrial automation monitoring loops.

1. Product Features

1.1 8-Channel Dedicated Acquisition for Multi-Type Weak Signals

Equipped with 8 independent input channels, it is specially designed for the acquisition of thermocouple (TC) and millivolt (mV)-level weak analog signals, and can be accurately adapted to various common types of thermocouple sensors and mV signal output devices in industrial sites. The channels adopt differential input design, which can effectively suppress common-mode interference, improve the stability and accuracy of signal acquisition, and accurately capture subtle signal changes generated by the conversion of on-site physical quantities such as temperature, meeting the stringent requirements of industrial process control for weak signal acquisition.

1.2 Support for Redundant Configuration to Improve System Reliability

It has flexible single-channel or redundant configuration modes, which can be deployed according to the system reliability requirements of industrial scenarios. In the redundant configuration mode, the module can realize automatic fault switching. When the primary channel or module fails, the standby channel or module can immediately take over the work, avoid signal acquisition interruption, greatly improve the continuous operation capability of the control system, and is especially suitable for key industrial control loops with extremely high requirements for operational stability.

1.3 Standardized Modular Design for Flexible Integration and Adaptation

Adopting the standard modular package design of the ABB S800 I/O series, it features convenient installation and can be easily integrated into industrial standard control cabinets and related control systems. It must be used with dedicated terminal units (TU830, TU833, TU842, TU843) to further ensure the stability of signal transmission and the standardization of wiring. The module is compatible with industry-standard fieldbus technology, can achieve high-efficiency communication with various process controllers of ABB and other manufacturers, has good system scalability and compatibility, and simplifies the system construction and upgrade process.

1.4 High Reliability and Strong Anti-Interference Capability

Manufactured using modern large-scale integrated circuit technology and strict production processes, the internal circuit integrates advanced anti-interference technology, has excellent anti-electromagnetic interference capability, and can operate stably in complex industrial electromagnetic environments. The rated isolation voltage reaches 50V, which can effectively block the impact of ground potential difference and external interference on signal acquisition, ensure the accuracy and reliability of collected data, and reduce the impact of environmental interference on system control accuracy.

1.5 Convenient Operation and Maintenance with Traceable Faults

The module supports online status monitoring and fault diagnosis functions, which can feed back its working status and channel acquisition status in real time. When detecting signal abnormalities, line faults, or module internal faults, it can timely feed back fault information to the upper-level control system, helping operation and maintenance personnel quickly locate fault points. At the same time, the module supports professional maintenance services, and the standardized maintenance process can ensure the rapid recovery of faulty modules, reducing the operation and maintenance cycle and costs.

2. Technical Parameters

2.1 Basic Parameters

Model: ABB AI843 3BSE028925R1
Product Type: Analog Input Module
Brand: ABB
Product Series: S800 I/O Series
Application Fields: Power industry, elevator industry, automobile and auto parts manufacturing, feed processing, aluminum smelting, refrigeration industry, iron and steel industry, combustion control systems, non-ferrous metal smelting, glass manufacturing, construction machinery, textile machinery, water treatment, etc.
Compatible Systems: ABB Advant 800xA System, ABB S800 I/O Distributed Control System, and various mainstream controllers
Number of Input Channels: 8 channels
Configuration Mode: Single-channel configuration/redundant configuration optional
Compatible Signal Types: Thermocouple (TC) signals, millivolt (mV) signals
Dedicated Terminal Units: Must be used with TU830, TU833, TU842, TU843 terminal units
Mounting Method: Standard modular mounting
Place of Origin: Imported
Customization: No
Warranty: Professional maintenance and warranty services provided
Net Weight: Approximately 0.4kg (subject to the actual product)
RoHS Compliance: Complies with relevant environmental protection standards
WEEE Category: Category 5 (small equipment with external dimensions not exceeding 50 cm in all aspects)

2.2 Electrical Parameters

Input Type: Differential input
Rated Isolation Voltage: 50V
Signal Acquisition Range: Adapted to the temperature range corresponding to thermocouples and mV-level signal range (subject to actual configuration)
Communication Interface: Compatible with industry-standard fieldbus interfaces, adapted to the S800 I/O system bus protocol
Power Supply Method: Powered via backplane bus or dedicated terminal unit
Power Consumption: Typical value ≤ 6W (full-load operation), maximum value ≤ 9W (subject to actual test)
Fault Diagnosis: Supports online status monitoring and fault feedback functions

2.3 Mechanical and Environmental Parameters

Dimensions (W×H×D): Conforms to the standard dimensions of the ABB S800 I/O series (subject to the actual product)
Operating Temperature: -25℃ ~ +70℃
Storage Temperature: -40℃ ~ +85℃
Relative Humidity: 5% ~ 95% RH (no condensation)
Electromagnetic Interference Resistance: Complies with relevant industrial-grade anti-interference standards
Vibration Resistance: Complies with IEC 60068-2-6 standard, 10-150Hz, acceleration 5g
Shock Resistance: Complies with IEC 60068-2-27 standard, acceleration 15g, duration 11ms
Protection Rating: IP20 (front-end protection after installation)
Housing Material: Flame-retardant engineering plastic + metal shielding cover

3. Working Principle

The core working logic of the ABB AI843 3BSE028925R1 analog input module is "Power Supply - Signal Acquisition and Adaptation - Signal Conditioning - A/D Conversion - Digital Transmission - Status Monitoring - Fault Feedback". The specific working process is as follows:

Power Supply and Initialization: The module obtains working power through the backplane bus or matched dedicated terminal units (TU830/TU833/TU842/TU843). The built-in stable power supply circuit provides stable power for the internal acquisition circuit, communication circuit, isolation circuit, etc. After power-on, the module automatically completes the initialization process, detects the internal circuit status, channel configuration parameters (single-channel/redundant mode), and the communication link with the upper-level system, preparing for signal acquisition.

Signal Acquisition and Adaptation: On-site industrial thermocouple sensors convert physical quantities such as temperature into mV-level analog signals, which are transmitted to the corresponding differential input channels of the module through dedicated signal cables. According to the preset channel configuration parameters, the module automatically adapts to the corresponding signal type and range, realizing the accurate acquisition of different types of weak analog signals. In the redundant configuration mode, the primary and standby channels perform signal acquisition and monitoring synchronously.

Signal Conditioning and Filtering: The collected weak analog signals are amplified and denoised by the channel signal conditioning circuit to remove noise components such as electromagnetic interference in the industrial field. At the same time, the built-in filter circuit performs smoothing filtering on the signals to further improve signal stability, ensure the accuracy of the collected signals, and provide high-quality analog signals for subsequent A/D conversion.

A/D Conversion and Digital Transmission: The conditioned analog signals are sent to the high-precision A/D conversion chip to convert analog signals into digital signals. The built-in microprocessor verifies and converts the format of the digital signals, and then transmits them to the upper-level control system (e.g., Advant 800xA System) through the system bus. In the redundant configuration mode, the data of the primary and standby channels are compared synchronously to ensure the reliability of data transmission.

Status Monitoring and Fault Feedback: The module monitors the signal amplitude and line connection status of each input channel in real time, as well as its own power supply status, communication status, and redundant working status. When detecting conditions such as signal abnormalities, channel disconnection, power supply abnormalities, communication abnormalities, or redundant switching triggers, it immediately generates fault information including fault type and fault channel, feeds it back to the upper-level control system through the bus, and triggers the local status indicator to alarm, reminding operation and maintenance personnel to handle it in a timely manner; automatic primary/standby switching is completed in redundant mode to ensure uninterrupted signal acquisition.

4. Common Fault Troubleshooting

Fault Phenomenon	Possible Causes	Troubleshooting and Solutions
No response when the module is powered on, and the status indicator light does not turn on	Abnormal power supply, loose backplane bus connection, failure of dedicated terminal units (e.g., TU830), damaged power connection cable, internal power circuit failure of the module	Use a multimeter to measure the supply voltage to confirm the normal output of the power supply; check whether the connection between the module and the backplane bus/dedicated terminal unit is firm, re-plug and tighten it; troubleshoot the working status of the dedicated terminal unit to confirm it is fault-free; check whether the power connection cable is damaged or broken, and replace it with a high-quality cable; if the above inspections are all normal but there is still no response, contact ABB professional maintenance services or authorized after-sales service for inspection and replacement.
Abnormal data collected by a certain channel (large deviation, large fluctuation)	Channel configuration error (mismatched signal type), incorrect sensor wiring (reversed positive and negative poles), sensor failure, damaged or poorly shielded signal cable, excessive electromagnetic interference on site	Check the configuration of the channel through the control system software to confirm that the signal type matches the actual sensor, reconfigure and save it; verify the sensor wiring to ensure correct connection of positive and negative poles; disconnect the connection between the channel and the sensor, connect a standard signal source to the channel for testing; if the data is normal, the fault lies in the sensor, and the sensor should be replaced; check whether the signal cable is damaged, ensure the use of shielded cables with the shielding layer reliably grounded at one end; check whether the module installation location is close to strong interference sources, install a metal shielding cover or optimize the installation location.
Failure to switch normally in redundant configuration mode	Incorrect redundant configuration parameters, communication link failure between primary and standby modules, abnormal adaptation of dedicated terminal units, outdated module firmware version	Check the redundant configuration parameters through the control system software to confirm that the addresses and communication parameters of the primary and standby modules are configured correctly, reconfigure and save them; check the communication link between the primary and standby modules to ensure a firm and fault-free connection; confirm that the dedicated terminal unit is compatible with redundant configuration and troubleshoot the working status of the terminal unit; check the module firmware version; if the version is outdated, contact ABB authorized after-sales service for firmware upgrade.
Communication abnormality between the module and the control system	Loose backplane bus connection, incorrect module address configuration, mismatched communication protocol, outdated module firmware version, control system interface failure	Re-plug the module to ensure a firm connection with the backplane bus; check the module address configuration to ensure it is consistent with the address allocation in the control system; confirm that the communication protocol configuration is correct and compatible with the upper-level control system; check the module firmware version; if the version is outdated, contact ABB professional maintenance services for firmware upgrade; if other modules communicate normally, the fault may lie in the module communication interface, and contact after-sales service for inspection and replacement.
The module frequently triggers fault alarms	Loose or oxidized channel wiring, damaged insulation layer of signal cable causing short circuit, excessive fluctuation of supply voltage, poor module grounding, internal circuit failure	Check whether the wiring of each channel is loose and whether the wiring terminals are oxidized; re-tighten the wiring or clean the oxide layer; check whether the insulation layer of the signal cable is damaged and replace it with an intact cable; measure the supply voltage to confirm no excessive fluctuation; install a voltage stabilizer if necessary; check whether the module grounding is reliable, re-tighten the grounding terminal to ensure the grounding resistance meets the requirements; if the above measures are ineffective, contact ABB authorized after-sales service for inspection and replacement.