ABB AI845 3BSE023675R1

Description

Product Overview

The ABB AI845 3BSE023675R1 is a high-density, multi-channel analog input module for the ABB Advant Controller 400 series and S400 I/O family, which are core components of the ABB Advant and MOD 300 distributed control systems (DCS). This module serves as a versatile and efficient interface for connecting a large number of analog field transmitters, providing critical process variable data to the controller for monitoring and control. The reliability of the ABB AI845 is essential for accurate data acquisition in continuous process industries.

• Product Type: Analog Input Module

• Compatible System: ABB Advant Controller 400 / S400 I/O, MOD 300 DCS

• Channels: 16 single-ended input channels.

• Input Signal Types: Configurable per channel for various standard industrial signals:

  • 4-20 mA (2-wire and 4-wire transmitter support)

  • 0-20 mA

  • 0-10 V DC

  • Resistance inputs (e.g., for Pt100 RTDs in 2- or 3-wire connection)

• Resolution: 15-bit analog-to-digital conversion (including sign bit), providing high measurement accuracy.

• Isolation: Channel-to-bus isolation (typically 500 V AC). Channels share a common ground and are not isolated from each other.

• Update Time: Scanning time is configurable and depends on the module setup and the controller’s cycle time.

• Diagnostics: Includes basic diagnostics for channel faults and communication errors.

• Connection: Uses a front-mounted, removable terminal block for field wiring.

• Configuration: Fully configured via the ABB engineering station software (e.g., Advant Station, Control Builder).

Advantages and Core Features

The primary advantage of the ABB AI845 3BSE023675R1 is its high channel density and configuration flexibility within the proven S400 I/O platform. It allows for a mix of current, voltage, and RTD signals on a single module, significantly reducing hardware variety and spare parts inventory. Its 15-bit resolution ensures precise measurement for demanding process applications. The module is designed for robust, maintenance-free operation in industrial environments and integrates seamlessly into the Advant control architecture. For existing systems, the AI845 offers a reliable and cost-effective solution for analog data acquisition.

Application Scenarios

This module is widely deployed in process industries with ABB Advant or MOD 300 systems for monitoring multiple analog points:

• Chemical & Petrochemical Plants: Monitoring temperatures (via RTD), pressures, levels, and flow rates across distillation columns, reactors, and storage tanks.

• Pulp & Paper Mills: Measuring analog signals from sensors on paper machines, in stock preparation, and for quality control.

• Pharmaceutical Production: Acquiring data from bioreactor sensors (temperature, pH, dissolved oxygen) and utility systems.

• Oil & Gas (Downstream): Interfacing with transmitters in refinery process units.

Comparison with Competing Products

Within its era, the ABB AI845 competed with analog input modules from other DCS vendors like Honeywell (TDC 3000), Siemens (Simatic S5), and Foxboro. Its strengths were its integration within the powerful Advant engineering environment and its flexible, high-density design. Compared to modern analog input modules (e.g., ABB’s own S800 I/O), the AI845 lacks features like individual channel-to-channel isolation and higher communication speeds. However, it remains a reliable and fully supported component within its legacy ecosystem, valued for its stability and familiarity.

Selection Guide and Important Notes

Selecting the ABB AI845 3BSE023675R1 is primarily for maintaining or expanding an existing Advant Controller 400 system. Compatibility with the specific CPU, I/O rack, and system software version must be verified.

Important Precautions:

• Common Ground Limitation: The 16 channels share a common analog ground (AGND). This module must not be used for signals from devices with different or floating ground potentials, as this will create ground loops and cause significant measurement errors. It is suitable for a group of transmitters all sharing the same system ground.

• Configuration is Mandatory: Each channel’s signal type (mA, V, RTD) and scaling must be correctly configured in the system’s hardware configuration database. An incorrect setting will render the channel useless or dangerous.

• RTD Wiring Limitations: When used for 2- or 3-wire RTDs, the module cannot compensate for lead wire resistance, which will introduce a measurement error. For high-accuracy temperature measurement, external transmitters are often preferred.

• Wiring Practices: Use proper shielded twisted-pair cables for analog signals. Maintain separation from power cables to minimize noise induction.

• Legacy Platform: The Advant 400/S400 platform is mature. Ensure long-term support and spares availability aligns with your plant’s lifecycle strategy.

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