ABB AI835A 3BSE051306R1 Analog Input Module

The ABB AI835A Thermocouple/mV Input Module is a key component in the hardware selection for the ABB Ability™ System 800xA® automation system, belonging to the S800 I/O series. Designed for high-precision temperature and millivolt-level signal measurement in industrial process control, this module provides 8 differential input channels supporting various thermocouple types and linear millivolt signals. It features high resolution, excellent noise immunity, and flexible cold junction compensation configuration, making it suitable for applications in industries such as power generation, chemicals, oil & gas, metallurgy, and pharmaceuticals where high reliability in temperature measurement is critical.

The AI835A module not only inherits all the functions of its predecessor, the AI835, but also extends support to Type D, L, and U thermocouples and offers improved temperature drift performance, reflecting ABB's technological expertise and continuous innovation in industrial automation measurement. The module adopts the standard S800 mechanical form factor and can be flexibly installed on various types of Module Termination Units (MTUs). It supports local or remote cold junction temperature measurement and features comprehensive diagnostics and status indication, meeting the modern industrial environment's demands for high performance, stability, and maintainability in signal acquisition modules.

2. Key Features and Benefits

1. High-Precision Multi-Channel Input: Provides 8 fully differential input channels. Each channel can be independently configured for various thermocouple types or linear millivolt signals in the range of -30 mV to +75 mV, meeting the needs for multi-point, multi-type temperature measurement.

2. Flexible Cold Junction Compensation (CJC): Channel 8 can be dedicated as the CJC channel, connected to a 4-wire Pt100 RTD (e.g., TY820) to provide an accurate ambient temperature reference for Channels 1 through 7. Users can also choose a fixed CJC temperature value or set it via the application, offering great flexibility in system configuration.

3. Wide Sensor Compatibility: Supports thermocouple Types B, C, E, J, K, N, R, S, T (same as AI835), and additionally supports Types D, L, U, covering a broad industrial temperature measurement range from -270°C to +2300°C.

4. Excellent Measurement Performance:

• High Resolution: 15-bit A/D converter provides fine measurement resolution.

• High Accuracy and Stability: Maximum error does not exceed 0.1%. Typical temperature drift is as low as 5 ppm/°C, ensuring long-term measurement accuracy.

• Strong Noise Immunity: Common Mode Rejection Ratio (CMRR) up to 120 dB, Normal Mode Rejection Ratio (NMRR) > 60 dB, effectively suppressing field electromagnetic interference.

5. Comprehensive Diagnostics and Monitoring:

• Module-Level Diagnostics: Monitors reference channels and power supply voltage.

• Channel-Level Diagnostics: Real-time monitoring for open-circuit (wire break) faults on input signals.

• CJC Channel Diagnostics: Monitors if the cold junction temperature is outside the valid range (-40°C to 100°C).

• Status Indication: The module front features three-color LEDs (Fault-Red, Run-Green, Warning-Yellow) for intuitive status feedback.

6. Robust Environmental Suitability and Certifications:

• Complies with multiple safety and explosion-proof certifications including CE, cULus (Class I Div 2 / Zone 2), and ATEX Zone 2.

• Certified by major marine classification societies such as ABS, BV, DNV, and LR, suitable for maritime applications.

• Operating temperature range 0 to +55°C, storage temperature range -40 to +70°C, meeting demanding industrial environment requirements.

• Compliant with RoHS and WEEE directives, reflecting environmental responsibility.

7. Easy Integration and Wiring:

• Compatible with various Module Termination Units (MTUs) like TUB10, TUB12, TUB14, TUB18, TUB30, TUB33, adapting to compact or extended installation needs.

• Provides clear terminal connection diagrams and multiple wiring methods (e.g., direct termination, D-Sub interface, connection to remote junction boxes), simplifying field installation.

• Maximum field cable length up to 600 meters, facilitating remote sensor placement.

3. Measurement Ranges and Linearization

The AI835A predefines precise measurement ranges and linearization curves for each input type, complying with international standards to ensure measurement accuracy and interchangeability.

Note: The user can independently select one sensor type from the table above for each channel.

4. Application Areas and System Integration

Typical Application Scenarios:

1. Industrial Furnace/Kiln Temperature Monitoring: Used in steel, cement, and glass manufacturing to measure temperatures in critical areas like high-temperature furnace chambers and rotary kilns.

2. Chemical Process Temperature Control: Monitors process medium temperature on equipment such as reactors, distillation columns, and heat exchangers to ensure reaction safety and efficiency.

3. Power Plant Thermal Systems: Monitors temperatures of boilers, steam pipes, turbines, etc., ensuring safe and efficient power plant operation.

4. Maritime and Ship Engineering: Used for temperature monitoring in engine rooms, boilers, exhaust gas systems, etc., meeting classification society rules.

5. Laboratory and Test Benches: Provides a reliable solution for R&D and test environments requiring high-precision, multi-channel temperature acquisition.

System Integration Key Points:

• Seamless Integration with ABB 800xA System: As part of System 800xA, it can be easily configured, parameterized, and diagnosed using the Control Builder engineering tool.

• Flexible Installation Options: Can select Compact MTUs (e.g., TU810/814/818) or Extended MTUs (e.g., TU830/833) based on field space and wiring requirements.

• Multiple Wiring Methods:

• Direct Terminal Connection (TU810/814/830/833): Suitable for direct connection of most field sensors.

• D-Sub Interface (TU812): Facilitates connection to remote junction boxes or equipment via prefabricated multi-core cables.

• Transmitter Connection (TU818): Simplifies connection to 2-wire transmitters without external marshalling.

• Shielding and Grounding Requirements: Shielded field cables are required for signal integrity, with proper shield connection. Thermocouple inputs can be configured for grounded or floating operation.