The DO810 module is a crucial component of the S800 distributed I/O series. It converts digital signals from the control system into 24V DC power signals usable by field devices. The module features a compact design and supports various Mounting Termination Units (MTUs), offering a flexible and efficient solution for plant digitalization and automation control.
A core feature of the module is its group isolation design: the 16 output channels are divided into two completely electrically isolated groups, each containing 8 channels and one independent process voltage supervision input. This design not only enhances system noise immunity and safety but also facilitates fault diagnosis and maintenance. If a power supply in one group fails, it does not affect the normal operation of the other group.
Furthermore, the DO810 incorporates comprehensive protection features, including short-circuit protection, overvoltage protection, overtemperature protection, and programmable Output Set as Predetermined (OSP) functionality, maximizing the safety of both field equipment and the control system itself.
2. Core Features and Benefits
High-Density Output Channels: Provides 16 independent digital output channels, achieving higher I/O point density within limited cabinet space, saving installation costs and space.
Group-Wise Electrical Isolation: Isolation between the two channel groups and to ground effectively prevents ground loop interference and fault propagation, enhancing system stability and safety in complex electromagnetic environments.
Comprehensive Diagnostics and Status Indication:
Channel Status LEDs: Each channel is equipped with an independent LED indicator for real-time output status display.
Module Status LEDs: Provide clear status indication for Fault (F), Run (R), Warning (W), and OSP active (O).
Process Voltage Supervision: Each group has a voltage supervision input. If the external 24V supply is lost, detailed channel error signals can be read via the ModuleBus for rapid fault localization.
Robust Protection Mechanisms:
Short-Circuit Protection: Outputs are protected against short circuits to ground and to 30V DC, with the short-circuit current limited to a maximum value.
Overtemperature Protection: Combines current limiting and temperature monitoring. When the output stage temperature exceeds 150°C, the channel automatically shuts down; it resumes automatically when the temperature drops to about 140°C, preventing permanent damage.
Overvoltage Protection: Capable of withstanding overvoltage surges within a specified range, protecting internal circuits.
Output Set as Predetermined (OSP): In the event of critical errors such as communication loss between the module and the controller, the programmable OSP function can automatically set all outputs to a predefined safe state (e.g., all ON or all OFF), preventing equipment from entering an uncontrolled dangerous state, meeting basic requirements for safety applications.
Excellent Drive Capability: Each channel offers a maximum continuous output current of 0.5A and low output impedance (<0.4Ω), capable of driving most industrial field actuators.
Flexible Connection Options: Compatible with various Mounting Termination Units (MTUs), including the compact TU810/TU814 (screw terminals), the TU812 with D-Sub connector, and the extended TU830/TU833, catering to different field wiring habits and space requirements.
Long-Distance Transmission Support: Supports a maximum field cable length of 600 meters, suitable for plants with widely distributed equipment.
3. Working Principle and Internal Structure
The DO810 module utilizes an advanced ASIC (Application-Specific Integrated Circuit) for core logic control. Its block diagram clearly illustrates the workflow: control commands and data from the ModuleBus are processed by the Backplane Interface Circuit (BIC) and the ASIC, which then drive the two independent high-side output driver groups.
Each driver group consists of 8 channels, with each channel integrating:
High-side driver with short-circuit and overtemperature protection: Responsible for power output.
EMC protection components: Suppress electromagnetic interference to ensure signal integrity.
Inductive load suppression circuitry: Absorbs back-electromotive force (EMF) generated when switching off inductive loads like relays or solenoids, protecting the output device.
Optical isolation barrier: Provides complete electrical isolation between the internal logic control circuitry (low-voltage side) and the external process power and load circuits (high-voltage side), ensuring system safety.
Status indicator LED: Directly displays the ON/OFF state of the channel.
The process voltage supervision inputs continuously monitor the externally supplied L1+ and L2+ power. If a power failure is detected, this information is immediately reported to the higher-level controller via the ModuleBus, and corresponding fault indications are given on the module's front panel.
4. Installation and Connection
The DO810 module itself does not connect directly to field cables; it must be installed on designated Mounting Termination Units (MTUs). Users can choose from the following MTUs based on different application scenarios and wiring needs:
TU810 or TU814 (Compact MTU): Uses traditional screw terminals for intuitive wiring, facilitating easy field installation and maintenance.
TU812 (Compact MTU with D-Sub Connector): Provides a 25-pin D-Sub (male) connector, suitable for applications requiring frequent connection/disconnection or the use of prefabricated cables, offering quick and reliable connections.
TU830 or TU833 (Extended MTU): Offers more terminal space, typically used for applications requiring higher density wiring or additional features (e.g., fuses). As shown in the diagrams, TU830/TU833 provides independent terminals for the power positive (L+) and return (L-) for each channel and can be optionally equipped with fuses (e.g., 6.3A), providing a higher level of protection.
During connection, it is essential to ensure that independent 24V DC power supplies are provided for each group (L1+/L1- and L2+/L2-), and that loads are connected correctly. Refer to the detailed terminal assignments and connection diagrams in the product manual (e.g., Figures 153, 154, 155).
5. Environmental Suitability and Industry Certifications
The design of the DO810 strictly adheres to international industrial standards. Its wide operating temperature range (0 to 55°C), high-level EMC immunity and emission standards enable it to perform in most industrial environments. The certifications it has obtained—CE, cULus, ATEX Zone 2, and several major marine classification societies (ABS, BV, DNV, LR)—signify that the product complies with stringent regulations in the EU, North America, hazardous areas, and the maritime sector, allowing for direct use in corresponding compliant projects.
6. System Compatibility
The DO810 is designed specifically for ABB Ability™ System 800xA® and Symphony Plus control systems, seamlessly integrating into S800 I/O stations. It communicates with the controller via the ModuleBus, fully leveraging the powerful engineering, operation, and diagnostic functions of the 800xA system. Its wide compatibility with various MTU types provides users with a complete solution ranging from compact to extended configurations.
7. Typical Application Areas
The DO810 module is widely used across various industrial fields requiring highly reliable digital outputs, including but not limited to:
Process Industries: Oil & Gas, Chemicals, Pharmaceuticals – driving valves, pumps, agitators, etc.
Power & Energy: Thermal, Hydro, Nuclear Power – controlling switchgear, excitation systems, auxiliary equipment.
Manufacturing: Automotive, Metals, Food & Beverage – controlling cylinders, conveyors, sorting devices on production lines.
Marine & Offshore: Based on its marine certifications, used for shipboard cabin control, ballast systems, alarm indication, etc.
Infrastructure: Water Treatment, Building Automation – controlling pumps, fans, lighting, etc.
