In modern distributed control systems (DCS), accurate and reliable analog signal acquisition is fundamental for process control, monitoring, and automation. The ABB AI810 (order code 3BSE008516R1) is a high-performance 8-channel analog input module designed for ABB’s S800 I/O architecture — widely used in systems like 800xA. This module supports both current and voltage inputs, incorporates strong protection features, and provides high resolution, making it suitable for a broad range of process automation applications.
In this article, we will explore the AI810’s specifications, key features, typical applications, installation and commissioning considerations, and the advantages it delivers in industrial systems.
Model: AI810
Part Number / Order Code: 3BSE008516R1
Platform: ABB S800 I/O
Number of Channels: 8 analog input channels
Signal Types Supported:
Current: 0–20 mA, 4–20 mA
Voltage: 0–10 V, 2–10 V (single-ended, unipolar)Resolution: 12-bit A/D conversion
Isolation: One group of 8 channels isolated from ground
The ABB AI810 is well-suited for a variety of industrial control and process automation use cases:
Process Control in DCS / 800xA Systems
Acquiring analog signals like process temperature, flow, pressure, or level (via 4–20 mA transmitters) in distributed control architectures.
Measurement of Sensor Voltages
Collecting voltage signals from sensors, transducers, or instrumentation that output 0–10 V or 2–10 V.
HART Instrumentation Integration
As the module supports HART communication tolerance, it can be used in systems with HART transmitters where both analog measurement and digital communication are required.
Long-Wire Field Applications
The ability to support 600 m cable distance enables implementation in widely distributed or remote measurement points, reducing the need for local signal conditioning.
Safety / Fault Monitoring Systems
With good diagnostic capability (short-circuits, input protection), the module is a reliable component in safety-relevant or fault-sensitive measurement systems.
Retrofitting / Expansion
When expanding an existing S800 I/O installation, AI810 modules can be added where needed for analog signal acquisition, without changing the architecture.
To get the most out of the AI810, here are key points for installation and commissioning:
Select the Appropriate MTU
Use one of the compatible termination units: TU810, TU812, TU814, TU818, TU830, TU833, TU835, TU838, TU850.
Choose the MTU based on your wiring topology and space constraints.
Wiring Considerations
Ensure field wiring uses correct cable type, gauge, and shielding if needed (especially over long distances).
Connect transmitter supply to L1+, L1- and/or L2+, L2- as supported by the module.
Avoid high-noise loops, and maintain proper grounding strategy.
Power Supply & ModuleBus
Confirm the ModuleBus +5 V and +24 V supply capacity to cater for the AI810’s consumption (~70 mA on +5V, ~40 mA on +24V).
Check for proper ModuleBus wiring and grounding.
Configuration
In your control system (e.g., ABB 800xA), configure the AI810 channels for the correct input type (current or voltage), range, and scaling.
Set up diagnostic monitoring, e.g., overrange, short-circuit, or transmitter supply faults.
Testing during Commissioning
Apply known analog signals (4–20 mA, 0–10 V) and verify that measured values match expected readings.
Simulate fault conditions (short to +24V, transmitter supply loss) to confirm protection operates as expected.
Check update cycle and latency to ensure that measurement speed is adequate for your control loops.
Maintenance
Periodically inspect for signs of stress, overheating, or unusual diagnostics.
Monitor long-term drift or calibration drift if precision is critical.
Keep a spare module if the process is critical and downtime must be minimized.
High Channel Count in Compact Module: With 8 analog inputs in a small footprint, it helps reduce I/O rack space and wiring complexity.
Robust Protection: Input protection (PTC, short-circuit) increases robustness and reduces risk of damage from faulty transmitters.
Long Wiring Capability: Supports field transmitters far from the I/O rack, enabling flexible system layouts.
HART Compatibility: Supports integration with smart HART transmitters without interfering with their communication.
Reliable Resolution & Accuracy: 12-bit resolution with low drift makes it reliable for process measurements.
Modular System Integration: Seamless integration into S800 I/O architecture, compatible with a variety of MTUs.
Diagnostic Capability: Group isolation and input protection help in detecting and diagnosing failures quickly.
Resolution: 12-bit resolution is good but may not be sufficient for very high-precision measurements; for more demanding applications, consider a higher-resolution module.
Unipolar Single-Ended Inputs: The AI810 only supports single-ended unipolar signals; if you need differential measurements, you’ll need a different module.
Operating Temperature Constraints: Specified up to +55 °C; environmental conditions must be within this range or managed properly.
No Intrinsic Safety: The module is not intrinsically safe — not suitable for use in hazardous zones without additional protection.
One Isolation Group: All 8 channels share the same isolated group, so a fault in one channel or group can affect diagnostics for the entire group.
Power and Bus Requirements: Must ensure your ModuleBus supply can accommodate the module's power consumption.
