The ABB 07 DI 92 is a high-density, high-performance digital input module specifically designed for the Advant Controller 31 system. Functioning as a remote module on the CS31 system bus, it provides 32 channels of 24 V DC digital inputs, making it suitable for the reliable acquisition and monitoring of large quantities of switch status signals in industrial automation control systems. The module features an advanced group-wise electrical isolation design, offering excellent noise immunity and system stability, making it an ideal choice for building highly reliable distributed I/O systems.
With its straightforward configuration, intuitive status indication, and rugged mechanical construction, this module is widely used in scenarios requiring centralized monitoring of numerous digital status signals. Applications include production line status monitoring, equipment alarm signal collection, safety interlock system inputs, and switch status detection in process control.
2. Core Features & Functions
2.1 High-Density Pure Digital Input Channels
The 07 DI 92 module is dedicated to digital signal input, providing 32 independent 24 V DC input channels. This high-density design significantly saves control cabinet space and system cost, allowing a single module to process status signals from up to 32 switches, sensors (e.g., proximity switches, photoelectric sensors), or relay contacts. It is particularly well-suited for applications with dense signal points.
2.2 Group-Wise Electrical Isolation for Enhanced System Reliability
The 07 DI 92 module's 32 input channels are divided into 4 groups of 8 channels each. The key design features are:
Inter-group Isolation: Complete electrical isolation is implemented between the four input groups.
System Isolation: All input groups are also isolated from the rest of the module's internal circuitry (e.g., power supply, bus interface).
Independent Reference Potentials: Each input group has its own separate reference potential terminal (ZP0, ZP1, ZP2, ZP3), allowing connection to signal sources with different ground potentials.
This isolation architecture effectively prevents a fault in one field signal loop (e.g., ground short, high-voltage intrusion) from causing the entire module or even the system to fail, significantly enhancing the overall robustness and availability of the system.
2.3 Bus Integration and Simple Configuration
Plug-and-Play: The module communicates with the central processing unit (e.g., 07 KR 91, 07 KT 9x series) via the standard CS31 system bus and requires no complex configuration data. Upon power-up, the central unit can access the status of all input channels.
Electrically Isolated Bus Interface: The CS31 bus interface is also electrically isolated from the module's input circuits and power supply, ensuring stable network communication and preventing field interference from affecting the bus via the I/O module.
Dual Address Occupancy: The module occupies two consecutive input address areas on the CS31 bus, corresponding to its 32 channels, providing clear and orderly addressing.
2.4 Clear Status Diagnostics and Indication
The front panel is designed for intuitive, rapid diagnostics:
32 Green LEDs: One-to-one correspondence with the 32 input channels, providing real-time, intuitive display of each channel's signal status ("1" or "0"), facilitating on-site commissioning and troubleshooting.
1 Red LED: Serves as the module-level error indicator, illuminating when a module internal error or CS31 bus communication fault is detected.
Test Button: Used to manually trigger the LED test function, allowing quick verification of all indicator lights. It can also display the current module's hardware address setting, simplifying installation and commissioning procedures.
3. Electrical Connection and Mechanical Installation
3.1 Interface Layout and Wiring
The 07 DI 92 module uses removable screw terminal blocks, providing secure and reliable connections for easy maintenance. The electrical connection diagram (Fig. 4.1-2) clearly shows the function of each terminal:
Power Terminals (X4): Provide 24 V DC operating power, featuring reverse polarity protection.
CS31 Bus Terminals (X1): For connecting to the system bus.
Signal Input Terminal Groups (X2, X3, X5, X6): Correspond to the four groups of 8 input channels and their respective independent reference potentials (ZPx).
Important Note: To ensure system safety, the process voltage (signal negative) must be included in the control system's grounding concept (e.g., grounding of the negative terminal).
Conductor Cross-Section Requirements:
3.2 Mechanical Installation
The module offers two flexible mounting options:
DIN Rail Mounting: Complies with DIN EN 50022-35 standard, using a rail with a depth of 15 mm.
Screw Direct Mounting: Fixed via the four M4 screw holes at the corners of the module.
Installation Dimensions: 120 mm (W) x 140 mm (H) x 85 mm (D)
Weight: Approx. 450 g
Recommended Mounting Orientation: Vertical installation, with connectors facing upward or downward to ensure effective heat dissipation via natural convection. Care must be taken during installation to ensure that cable ducts or other additional components inside the cabinet do not obstruct the module's ventilation.
4. Addressing
Each 07 DI 92 module must be assigned a unique address to allow the central unit to correctly identify and access it. Address setting is accomplished using the DIL rotary coding switch located under the slide cover on the right side of the module.
Address Activation Timing: The module reads the coding switch setting only during the initialization phase after power is applied. This means that changes to the address setting during operation are ineffective; a power cycle is required for the new setting to take effect.
Switch Setting Rules:
Use switches 2 through 7 to set the module base address n.
Switches 1 and 8 must be set to the OFF position.
Recommended Addresses: When using 07 KR 91 or 07 KT 92 to 97 as the bus master, even-numbered addresses are recommended, e.g.: 08, 10, 12, ... , 60.
Channel Addressing: After setting the base address n, the module's 32 input channels will occupy two consecutive input address areas, n and n+1. The specific correspondence between channels, terminals, and addresses is detailed in the address assignment table in the manual (Fig. 4.1-3).
5. Operation and Diagnostic Displays
5.1 Normal Operation
Power-on Initialization: After power is applied, the module initializes automatically. All LEDs will illuminate briefly during this time.
Bus Status Indication: The red LED (③) flashes to indicate that the CS31 system bus is not operating normally. This red light turns off when bus communication is normal and the module has no internal errors.
Signal Status Display: The 32 green LEDs (①) continuously display the real-time logic state of their corresponding input channels (ON = logic "1", OFF = logic "0").
5.2 Diagnostic and Test Functions
Pressing the test button on the front panel executes the following functions:
LED Test: The first press of the button triggers the LED test mode. All green and red LEDs should illuminate, verifying that the indicators are functional.
Address Display: Following the LED test, green LEDs 00 through 07 will display for approximately 3 seconds, indicating the current setting of the address coding switches (switches 1 through 8) in binary form (LED 00 corresponds to switch 1, and so on). This feature is very useful for on-site confirmation or identification of the module address.
6. Application Scenarios and Key Advantages
Typical Application Scenarios:
Manufacturing Execution Systems (MES): Collecting equipment run status, material presence, door switch status signals from various production line stations.
Process Monitoring: Monitoring run/stop feedback signals for pumps, fans, valves; collecting status from level switches, flow switches, pressure switches.
Safety Systems: Serving as an input interface for safety relay or emergency stop button signals, integrated into safety control loops (requires appropriate safety architecture).
Energy Management: Collecting auxiliary contact status from circuit breakers and contactors in distribution cabinets for energy monitoring and fault diagnosis.
Core Advantages:
High Reliability: Group-wise electrical isolation design effectively suppresses common-mode interference, prevents fault propagation, and ensures long-term stable system operation.
High Density and Cost-Effectiveness: A single module integrates 32 input points, significantly improving cabinet space utilization and cost-per-point efficiency.
Ease of Use and Maintenance: No software configuration required, plug-and-play; front-panel LED status is clear at a glance; test button facilitates quick diagnostics; removable terminals simplify wiring and maintenance.
Rugged and Durable: Wide operating temperature range, industrial-grade design suitable for harsh industrial environments.
Seamless System Integration: As a member of the Advant Controller 31 system family, it is fully compatible with the same series of controllers, buses, and software tools, ensuring efficiency throughout the entire project lifecycle from design and installation to maintenance.
7. Ordering Information
Product Type: 07 DI 92
Order Number: GJR5 2524 00 R0101
Delivery Scope Includes:
Digital Input Module 07 DI 92
1 x 5-pin connector (grid space 5.08 mm)
1 x 3-pin connector (grid space 5.08 mm)
4 x 10-pin connectors (grid space 3.81 mm)
