ABB AI830 63938751 – 16-Channel Analog Input Module (S800 I/O Series)
Introduction
The ABB AI830 (Order Code: 63938751) is a high-performance 16-channel analog input module designed for the S800 I/O distributed I/O platform. It is widely used in process automation systems such as ABB 800xA, AC 800M, and Freelance, enabling accurate acquisition of industrial analog signals such as temperature, pressure, flow, pH, and vibration feedback.
The module provides flexible input scaling, high noise immunity, and advanced diagnostics, making it suitable for demanding industrial and utility environments.
Product Highlights
16 individually isolated analog channels
Supports 0–20 mA / 4–20 mA current loop input
High 15-bit resolution A/D conversion
Open circuit supervision (per channel)
Galvanic isolation for noise reduction and equipment protection
Hot-pluggable module for live replacement
Automatic addressing via terminal base
Status LEDs for module and channel condition monitoring
Coated PCB for extended lifespan in harsh environments
Technical Parameters (Table Format)
| Parameter |
Specification |
| Channels |
16 analog inputs |
| Input Types |
0–20 mA, 4–20 mA (current loop) |
| Resolution |
15 bits |
| Accuracy |
±0.1% of full scale |
| Input Impedance |
250 Ω nominal |
| Isolation |
500 V (I/O to system) |
| Power Consumption |
0.9 W typical |
| Operating Temperature |
−25°C to +70°C |
| Field Wiring |
Shielded twisted-pair recommended |
| Compatible Terminals |
TU830 / TU833 / TU835 |
| Diagnostics |
Open-wire, module fault, channel alarm |
| System Compatibility |
ABB 800xA, AC 800M, Freelance, Harmony |
Internal Architecture & Design
Multi-channel A/D Converter – Converts analog signals to digital values
Channel Protection Network – Protects against surges and wiring faults
Backplane Interface – Handles data transfer to CPU / communication unit
Per-Channel LEDs – Provide instant diagnostics for signal loss or errors
Galvanic Isolation Barrier – Ensures safe separation between field and controller
Application Areas
Refineries, chemical & petrochemical plants
Power generation (turbine control, balance-of-plant feedback)
Water & wastewater process automation
Food and pharmaceutical production lines
HVAC and environmental monitoring
Paper mills, steel plants, mining operations
Installation Guidelines
Mount on TU8xx terminal base before applying system power
Use shielded analog signal cabling to minimize EMI interference
Ensure proper grounding for shield drain wires (single-end ground recommended)
Configure scaling and alarm limits via ABB engineering software (Control Builder / 800xA System Workplace)
Perform loop calibration before commissioning plant-wide I/O
Maintenance & Reliability
Supports online replacement (hot swap) without process interruption
Self-diagnostic alarms visible in 800xA asset management
Module coating prevents corrosion in high-humidity or gas-exposed environments
Recommended spare level: 1 spare for every 15–20 modules deployed
Periodic check: verify loop integrity and wiring resistance every 12–24 months
Additional Notes
The part number 63938751 refers to the commercial order code; functionally identical to standard AI830
Frequently paired with AO801, DI801, DO820, CI801 in distributed S800 racks
One of ABB’s most commonly used analog input modules due to high channel density and stability
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