Description

ABB AI835 3BSE008520R1

ABB AI835 3BSE008520R1 is an analog input module dedicated to receiving analog signals output by various industrial sensors such as those for temperature, pressure, flow rate, and liquid level. Through its internal precision signal conditioning, isolation, and A/D conversion circuits, it converts analog signals into digital signals recognizable by controllers, providing reliable data support for industrial scenarios including process control, data monitoring, and fault early warning. Equipped with multi-channel acquisition capability, flexible signal adaptation features, and basic diagnostic functions, it adopts an industrial-grade stable design and is widely used in fields with high requirements for signal acquisition stability, such as machinery manufacturing, power distribution, municipal engineering, and light industry. It can be seamlessly integrated with ABB series controllers and dedicated terminal units to ensure the efficient and stable operation of automated systems.

With its input-output isolation design, electromagnetic interference resistance optimization, and modular architecture, the AI835 3BSE008520R1 module effectively improves its adaptability to complex industrial environments and ease of operation and maintenance. It is compatible with multiple standard analog signal types and can flexibly meet the access requirements of different sensors, making it a cost-effective choice for medium-to-high precision analog acquisition scenarios in the industrial automation field.

I. Product Features

1. Multi-channel Acquisition with Flexible Signal Adaptation

Equipped with 8 analog input channels configurable for single-ended/differential mode, it supports multiple standard analog signal types including 4-20mA and 0-20mA current signals, 0-10V and 1-5V voltage signals, and is also compatible with signal input from thermal resistance temperature sensors (e.g., Pt100, Cu50). The channels can be flexibly configured as single-ended or differential mode according to actual application scenarios to adapt to the signal output characteristics of different sensors, improving the flexibility of system deployment.

2. High-precision Conversion for Reliable Data Acquisition

Adopting a 12-bit high-resolution A/D conversion circuit, it achieves a measurement accuracy of ±0.1% FS with low zero drift and gain drift characteristics, enabling accurate capture of weak signal changes. Targeting interference signals in industrial sites, it has built-in multi-stage filter circuits that can effectively filter electromagnetic interference and noise, ensuring the stability and reliability of collected data and providing high-quality raw data for control systems.

3. Isolation Protection Design with Strong Anti-interference Capability

It adopts a dual isolation design between input and output, as well as between input and power supply, with a rated isolation voltage of up to 50V AC. This effectively prevents external signal interference, ground loops, and voltage fluctuations from affecting the module and the backend control system. It also features a current-limited transmitter power supply function, which can provide stable 24V DC power for front-end two-wire sensors and is equipped with an overcurrent protection mechanism to prevent module damage caused by sensor overload or short circuit.

4. Basic Onboard Diagnostics for Efficient Operation and Maintenance

Built-in basic onboard diagnostic functions can real-time monitor the module's own power supply status, A/D conversion circuit working status, and input signal integrity (e.g., signal overrange, open circuit). When an abnormality is detected, it immediately generates fault information and feeds it back to the control system, while triggering local alarm indicators, facilitating maintenance personnel to quickly locate the fault range (module-level, channel-level) and shortening system downtime.

5. Modular Architecture with Good Compatibility and Scalability

As a standard module of the ABB S800 I/O series, it adopts a modular design and supports DIN rail mounting, enabling flexible integration into standard distribution cabinets. It is fully compatible with the ABB 800xA distributed control system and needs to be used with dedicated terminal units of the S800 I/O series (e.g., TU 810, TU 812, etc.). It also supports connection with third-party control systems through standard communication protocols, providing convenience for system expansion, upgrading, and transformation.

6. Wide Operating Temperature Range with Strong Environmental Adaptability

Using industrial-grade high-quality components and sealed packaging technology, it has an operating temperature range of -25℃~+70℃, and can adapt to various industrial environments such as high temperature, low temperature, and high humidity. It has a certain level of vibration and shock resistance, meeting the stringent operation requirements of industrial scenarios and ensuring long-term stable operation under complex working conditions.

II. Technical Specifications

1. Basic Parameters

Model: ABB AI835 3BSE008520R1
Product Type: Analog Input Module
Product Series: ABB S800 I/O Series
Brand: ABB
Application Fields: Machinery Manufacturing, Power Distribution, Municipal Engineering, Light Industry, Automated Production Lines
Compatible Systems: Industrial automation systems such as ABB 800xA Distributed Control System
Compatible Terminal Units: S800 I/O series terminal units such as TU 810, TU 812, TU 814
Mounting Method: DIN Rail Mounting (Compliant with EN 50022 Standard)
Net Weight: Approximately 0.32kg
Warranty Period: 12 Months
RoHS Compliance: Conforms to EU Directive 2011/65/EU (RoHS 2.0)
WEEE Category: Category 5 (Small Electronic Equipment)

2. Electrical Parameters

Number of Input Channels: 8 Channels (Configurable for Single-ended/Differential Mode)
Input Signal Types: Current signals (4-20mA, 0-20mA), Voltage signals (0-10V, 1-5V), Thermal resistors (Pt100, Pt1000, Cu50, Cu100)
Resolution: 12-bit
Measurement Accuracy: ±0.1% FS (Current/Voltage signals), ±0.2℃ (Temperature signals, Pt100, -100℃~+600℃)
Isolation Class: Isolation between input and output, input and power supply, rated isolation voltage 50V AC (Continuous)
Transmitter Power Supply: 24V DC, current limit ≤20mA per channel
Communication Protocol: Compatible with industrial standard protocols such as Modbus
Power Consumption: Typical value ≤4W (Full-load operating condition)
Response Time: ≤20ms (Current/Voltage signals), ≤1s (Temperature signals, Pt100)

3. Mechanical & Environmental Parameters

Dimensions (W×H×D): 45mm×119mm×100mm
Operating Temperature: -25℃~+70℃
Storage Temperature: -40℃~+85℃
Relative Humidity: 5%~95%RH (Non-condensing)
Electromagnetic Immunity: Compliant with EN 55011 Group 1 Class A, EN 61000-4-2 (ESD), EN 61000-4-4 (Electrical Fast Transient) standards
Vibration Resistance: Compliant with IEC 60068-2-6 standard, 10-150Hz, acceleration 5g
Shock Resistance: Compliant with IEC 60068-2-27 standard, acceleration 15g, duration 11ms
Protection Class: IP20 (Front-end protection after DIN rail mounting)

III. Working Principle

The core working logic of the ABB AI835 3BSE008520R1 analog input module follows the sequence of "Signal Access - Power Supply Guarantee - Conditioning & Preprocessing - Conversion & Transmission - Status Monitoring - Diagnostic Feedback". The specific workflow is as follows:

Signal Access and Power Supply Guarantee: Analog signals output by front-end industrial sensors (e.g., pressure sensors, thermal resistors, etc.) are connected to the module's 8 input channels via dedicated terminals, and the single-ended or differential wiring mode can be selected according to the signal type. The module provides stable 24V DC power for sensors requiring power supply (e.g., 4-20mA two-wire sensors) through its built-in current-limited power supply circuit, while limiting the output current to avoid module damage caused by sensor short circuit or overload.
Signal Conditioning and Preprocessing: The accessed analog signals first pass through the module's internal dedicated conditioning circuits and are processed specifically for different signal types—current signals are converted into voltage signals via precision resistors; thermal resistance temperature signals undergo signal amplification and linearization processing. At the same time, electromagnetic interference from industrial sites (e.g., interference generated by frequency converters and relays) is removed through filter circuits. Electrical isolation between input signals and backend circuits is then achieved through isolation circuits, further improving signal stability and system safety.
A/D Conversion and Data Transmission: The preprocessed standard analog signals are sent to the 12-bit high-precision A/D conversion circuit and converted into digital signals. After being processed by the module's internal logic circuit, the digital signals are transmitted to controllers such as ABB 800xA via the S800 I/O system bus, providing data support for the decision-making and control of the control system.
Status Monitoring and Diagnostic Feedback: The module real-time monitors its own power supply voltage, A/D conversion circuit working status, and input signal integrity of each channel (e.g., overrange, open circuit). When an abnormality is detected, it immediately activates the onboard diagnostic mechanism, generates fault information including fault location and type, feeds it back to the control system via the communication link, and triggers corresponding local alarm indicators (power alarm, channel alarm) to remind maintenance personnel to handle the problem in a timely manner.

IV. Common Troubleshooting

Fault Phenomenon	Possible Causes	Troubleshooting and Solutions
Power indicator not lit, module unresponsive	Abnormal power supply (power failure, voltage out of range), loose or reversed polarity of power terminal wiring, poor connection between module and terminal unit, internal power circuit failure of the module	Use a multimeter to measure the voltage at the module's power terminals to ensure it meets the 24V DC±10% requirement; check if the power terminal wiring is firm and verify the correctness of polarity connection; inspect the connection between the module and the terminal unit to ensure it is properly seated and firm, re-plug to confirm reliable connection; if the above checks are all normal but the module remains unresponsive, internal power circuit failure may be the cause—contact ABB authorized after-sales service for repair or replacement.
Large deviation in collected data, unstable signals	Loose or poor connection of input signal cables, incorrect wiring mode (confusion between single-ended and differential mode), poor or ungrounded shielded cables, external electromagnetic interference, uncalibrated module or lost calibration parameters, sensor malfunction, ambient temperature beyond the module's adaptive range	Re-tighten the input signal terminal wiring and verify that the wiring mode matches the signal type (correct selection of single-ended/differential mode); check whether shielded cables are used for signal cables and ensure the shielding layer is grounded at one end (grounding at the controller end is recommended), keep away from strong interference sources such as frequency converters and high-voltage cables; calibrate the module's precision with a standard signal source and restore calibration parameters; connect the sensor to other normal channels for testing to determine if it is faulty, replace it if necessary; check the module's operating ambient temperature and take cooling or heat preservation measures if it exceeds the -25℃~+70℃ range.
No data collected from specific channels, channel alarm indicator lit	Loose or broken wiring of the channel, sensor malfunction or no power supply, incorrect wiring mode configuration, internal damage to the module channel	Re-tighten the signal wiring of the channel and check for cable breaks; inspect whether the corresponding sensor of the channel is powered normally, connect the sensor to other normal channels for testing to determine if it is faulty, repair or replace it if necessary; verify that the wiring mode configuration of the channel is correct and matches the signal type; if the above checks are all normal, internal damage to the module channel may be the cause—contact ABB authorized after-sales service for repair.
Abnormal temperature signal collection (e.g., large display deviation, no display)	Incorrect thermal resistor wiring (e.g., three-wire system connected as two-wire system), thermal resistor damage, module temperature signal conditioning circuit failure, loss of calibration parameters	Verify that the thermal resistor wiring method is correct (three-wire/four-wire system), ensure cable resistance matching, re-wire and fasten the connection; connect the thermal resistor to other normal channels for testing to determine if it is damaged, replace it if necessary; calibrate the module's temperature acquisition function with a standard temperature source and restore calibration parameters; if both the sensor and wiring are normal, module temperature signal conditioning circuit failure may be the cause—contact after-sales service for repair.
Module frequently triggers overall alarm, multi-channel data abnormal	Excessive fluctuation of module power supply voltage, poor connection between module and terminal unit, strong external electromagnetic interference, overall loss of module calibration parameters	Measure the module's power supply voltage, install a voltage stabilizer at the front end if the fluctuation is excessive; check the connection between the module and the terminal unit, re-plug and fasten it; strengthen electromagnetic interference protection, check the grounding of shielded cables and cable layout, keep away from strong interference sources; perform overall precision calibration on the module and restore calibration parameters; if the alarm is still frequent after calibration, contact after-sales service for further troubleshooting of module faults.