ABB AI930S 3KDE175511L9300 Analog Input Module

The AI930S (AI4H‑Ex) is a high-performance, highly reliable analog input module within the ABB Ability™ System 800xA® and S900 Remote I/O family, designed specifically for industrial process control and automation applications. The module features four independent 4…20 mA current signal input channels and integrated HART® communication protocol support, enabling direct connection to smart transmitters for dual functionality of analog signal acquisition and digital information exchange.

Belonging to the S900 I/O Type S series, the AI930S is designed for installation in hazardous areas (Zone 1) and can connect to intrinsically safe (Ex i) field devices. It is suitable for industries with stringent safety and reliability requirements, such as oil & gas, petrochemical, pharmaceutical, and power generation. The module supports PROFIBUS‑DP/DPV1 fieldbus communication, allowing seamless integration with ABB control systems like AC800M, AC800F, and AC870P, as well as third-party PROFIBUS master systems via GSD files or DTM tools.

The module incorporates advanced features like electrical isolation, line monitoring, fault diagnostics, Hot Swap, and Hot Configuration In Run (HCIR), enhancing system availability while significantly reducing installation, commissioning, and maintenance costs. Its robust construction is complemented by a G3 corrosion protection coating, making it suitable for harsh industrial environments.

2. Key Features and Benefits

2.1 Intrinsically Safe Design & High Reliability

The AI930S is ATEX certified for use in Zone 1 hazardous areas. It can be installed directly in the field, reducing signal cable lengths, marshalling cabinets, system costs, and potential failure points. Full electrical isolation (input-bus-power) within the module effectively prevents ground loop interference and common-mode voltage effects, ensuring accurate signal acquisition.

2.2 Integrated HART Communication Capability

The module features a built-in Primary HART Master, enabling direct communication with HART smart devices via the 4…20 mA loop, supporting:

• Cyclic HART Variable Reading (up to 8 floating-point variables, e.g., temperature, pressure, flow)

• HART Status Polling (real-time detection of device alarms, configuration changes, communication errors)

• Acyclic HART Parameter Configuration (via DTM tools or DPV1-compatible masters)

2.3 High Accuracy and Stability

The module utilizes a 16-bit ADC converter. Measured values are transmitted in μA (e.g., 4 mA corresponds to 4000). It supports two selectable measuring ranges: 0…20 mA and 4…20 mA. A configurable PT1 filter algorithm (time constants: 0.1 s to 29.2 s) is built-in to effectively suppress field noise and enhance signal stability.

2.4 Flexible Configuration and Parameterization

Two parameterization modes are supported:

• Mode 1: Unified parameter settings at the module level, suitable for rapid deployment.

• Mode 2: Independent parameter settings per channel, allowing flexible configuration of measuring ranges, filter times, fault substitute values, etc.

2.5 Comprehensive Diagnostics and Monitoring

• Line Monitoring: Supports diagnostics for wire break (< 2 mA), short circuit (< 1.5 V), overload, etc.

• HART Communication Status Monitoring: Provides real-time feedback on device communication anomalies or status bit changes.

• Module Health Status: Reports module and channel faults via standard PROFIBUS diagnostic telegrams.

2.6 Redundancy and High Availability

Supports power redundancy and communication redundancy (requires a redundant communication interface CI920). Features Hot Swap and Hot Configuration In Run (HCIR), allowing module replacement or configuration changes during system operation, significantly improving system uptime.

2.7 Easy Installation and Maintenance

Utilizes the unified mechanical design and terminal blocks of the S900 series, supporting DIN rail mounting. Status LEDs on the module front facilitate quick on-site diagnostics. When used with ABB's DTM tools or SMART VISION software, graphical configuration, real-time monitoring, and historical data analysis are enabled.

2.8 System Integration Advantages

• Fully compatible with large-scale DCS systems like ABB System 800xA and Symphony Plus.

• Standard GSD files provided for easy integration into third-party PROFIBUS networks.

• Supports the FDT/DTM framework for unified device type management and parameter configuration.

  
  

3. Application Areas

The AI930S module is widely used in the following industrial scenarios:

1. Process Control
   For acquiring analog signals such as temperature, pressure, flow, and level. Applicable in refining, chemical, pharmaceutical, and water treatment industries.

2. Safety Monitoring Systems
   Connecting intrinsically safe sensors in hazardous areas for real-time monitoring of safety parameters like gas concentration, flame, and vibration.

3. Environmental Monitoring & Energy Management
   Collecting energy consumption data (e.g., current, power factor) and emission parameters (e.g., SO₂, NOₓ) to support energy efficiency analysis and environmental compliance.

4. Equipment Health Management
   Reading internal device status via HART variables (e.g., valve position, actuator temperature, sensor lifespan) to enable predictive maintenance.

   
   

4. Installation and Connection Guidelines

4.1 Electrical Connection Considerations

• The AI930S is an active input module that provides loop power (approx. 15 VDC) for 2-wire transmitters.

• The total loop voltage drop must be calculated:
  Utotal=Utransmitter+Imax×Rcable≤15VUtotal=Utransmitter+Imax×Rcable≤15V

• If multiple transmitters share a common ground, it is recommended that the transmitters have output-side electrical isolation to avoid measurement errors caused by ground loops.

4.2 Connection of Intrinsically Safe Devices

When connecting intrinsically safe devices in Zone 0/1, EN 50039 standards must be followed. Compare the following parameters:

• Module Output: Uo,Io,Po,Lo,CoUo,Io,Po,Lo,Co

• Device Input: Ui,Ii,Pi,Li,CiUi,Ii,Pi,Li,Ci

• Cable Parameters: Lc,CcLc,Cc

Ensure Uo≤UiUo≤Ui, Io≤IiIo≤Ii, Lo≥Li+LcLo≥Li+Lc, Co≥Ci+CcCo≥Ci+Cc.

4.3 Cable Selection and Wiring

• Use shielded twisted-pair cables with single-point grounding of the shield.

• Avoid running parallel to power cables; maintain a minimum separation of ≥30 cm.

• Keep cable lengths as short as possible to minimize voltage drop and noise interference.

  
  

5. Parameter Configuration and Data Mapping

5.1 GSD File Selection

• ABB_04D2.GSD: Mode 2 (channel-wise parameterization, English)

• ABB_04D2.GSG: Mode 2 (German)

• ABB104D2.GSD: Mode 1 (module-wise parameterization, English)

• ABB104D2.GSG: Mode 1 (German)

5.2 Measuring Range and HART Enable

5.3 Filter / Damping Setting

Selectable filter time constants: OFF, 0.1 s, 2.6 s, 29.2 s.
When HART communication is enabled, a filter setting ≥100 ms is recommended to ensure signal stability.

5.4 Fault Substitute Value Strategy

• Min Value: Outputs 3.6 mA (for 4…20 mA range) or 0 mA (for 0…20 mA range) on error.

• Max Value: Outputs 22 mA on error.

• Last Valid Value: Holds the last valid sampled value.

  
  

6. Diagnostics and Maintenance

6.1 Status Monitoring and Alarms

The module reports real-time status via PROFIBUS diagnostic telegrams, including:

• Power supply anomalies

• Communication interruptions

• Channel wire break / short circuit / overload

• HART device communication faults

• Module overtemperature

6.2 Troubleshooting Steps

1. Check power supply and wiring connections.

2. Verify PROFIBUS address and baud rate settings.

3. Use DTM or SMART VISION to read detailed diagnostic information.

4. Verify if the transmitter supply voltage meets requirements.

5. Confirm HART device address and communication parameters.

6.3 Hot Swap Procedure

1. Ensure the Hot Swap function is enabled in the control system.

2. De-energize or place the affected part of the control system in maintenance mode.

3. Remove the faulty module and insert the replacement module.

4. The system automatically recognizes and restores communication without requiring a configuration download.

   
   

7. Compatibility and System Integration

7.1 Integration with ABB Control Systems

• AC870P: Integrated via DTM, supports LSB status format, automatic data scaling.

• AC800F: Uses GSD import or templates; MSB status format is recommended.

• AC800M: Integrated via HWD files, supports percentage scaling and status fusion.

7.2 Third-Party System Integration

• Standard PROFIBUS GSD files are provided, compatible with most mainstream PLCs and DCSs.

• Advanced configuration and diagnostics can be achieved via the FDT/DTM framework.

7.3 Software Tool Support

• ABB Device Library: Contains complete DTM suite and icons.

• SMART VISION: For HART device configuration and monitoring.

• Control Builder: For programming and hardware configuration of AC800 series.