Description

Product Overview

ABB AI880A 3BSE039293R1 is a high-performance industrial analog input module,engineered as a core signal acquisition component of ABB’s distributed control systems(DCS)—specifically optimized for capturing and processing high-precision analog signals from field sensors in critical industrial workflows.As a pivotal”signal bridge”in ABB’s automation portfolio,this module addresses key industrial challenges:ensuring ultra-accurate conversion of process variables(temperature,pressure,flow)into digital data,withstanding harsh operating conditions in power plants,oil&gas facilities,and chemical plants,and enabling seamless integration with ABB’s AC 800M DCS and Symphony Plus systems.

Leveraging ABB’s advanced signal processing technology,the AI880A 3BSE039293R1 integrates 8 independent analog input channels,high-resolution converters,and robust noise-suppression mechanisms—all tailored to the low-error,high-stability demands of process control.Its ruggedized design resists temperature fluctuations,electrical interference,and mechanical vibration,while its modular architecture simplifies retrofitting into existing ABB control cabinets.Whether monitoring steam pressure in power plants,tracking flow rates in oil pipelines,or measuring pH levels in chemical reactors,this module ensures consistent,reliable signal acquisition—laying the foundation for precise process regulation and safe industrial operation.

Technical Specifications

Parameter Name

Specification

Product Model

ABB AI880A 3BSE039293R1

Component Type

High-Performance Industrial Analog Input Module

Compatibility

ABB AC 800M DCS,ABB Symphony Plus Systems,ABB Compact Control Systems

Core Function

Analog Signal Acquisition,High-Precision A/D Conversion,Noise Filtering,Fault Diagnostics

Circuit Technology

Surface-Mount Technology(SMT);6-Layer PCB(FR-4 High-Temperature Substrate)

Input Channels

8 Independent Analog Input Channels(Configurable per Channel)

Supported Input Types

4-20mA DC,0-20mA DC,0-10V DC,±5V DC,±10V DC,Thermocouple(Type J/K/T/E/R/S/B/N),RTD(Pt100/Pt1000)

Communication Interface

ABB proprietary PROFIBUS DP(for DCS Integration),Local Bus for Module Chaining

Operating Temperature Range

-25°C~+70°C

Storage Temperature Range

-40°C~+85°C

Power Requirements

24V DC±15%,1.2A Max(Typical:0.8A)

Power Consumption

Typical:19.2W;Maximum:28.8W

Protection Features

Overvoltage Protection(30V DC per Channel),ESD Protection(±25kV Contact),Short-Circuit Protection,Reverse Polarity Protection

Physical Dimensions

140mm×90mm×22mm(L×W×H)

Net Weight

Approximately 280g

Standards Compliance

IEC 61131-2,IEC 61000-6-2,CE,RoHS,UL 508,ATEX Zone 2,IECEx Zone 2

Vibration Resistance

15g(10-2000Hz,3 Axes)

Shock Resistance

50g(1ms Pulse,3 Axes)

MTBF(Mean Time Between Failures)

≥150,000 Hours

Signal Conversion Accuracy

24-Bit Resolution;±0.01%Full Scale(for 4-20mA Signals);±0.1°C(for RTD/Thermocouple)

Sampling Rate

Up to 100 Samples per Second(per Channel,Configurable)

Main Features and Advantages

Ultra-High Precision Signal Conversion:Equipped with 24-bit analog-to-digital(A/D)converters and advanced linearization algorithms,the module delivers±0.01%full-scale accuracy for 4-20mA process signals—critical for applications like turbine speed monitoring and chemical concentration control.For temperature measurements,it ensures±0.1°C accuracy with RTD/thermocouple inputs,eliminating errors in heat-sensitive processes.

Multi-Type Input Flexibility:Each of the 8 channels can be independently configured for different input types(current,voltage,thermocouple,RTD)via ABB’s Control Builder M software—no hardware modifications required.This eliminates the need for multiple specialized modules,reducing inventory costs and simplifying system design for mixed-signal environments.

Robust Noise Suppression:Integrated 50/60Hz notch filters and low-pass filters suppress electrical interference from nearby motors,drives,and power lines—ensuring stable signal acquisition even in high-EMI industrial environments(e.g.,steel mills,power plant switchyards).The module’s isolated input design(2.5kVrms channel-to-channel isolation)prevents ground loops and cross-talk between channels.

Industrial-Grade Durability:Built with a 6-layer FR-4 PCB substrate,high-temperature-resistant components,and nickel-plated terminals,the module withstands extreme temperatures(-25°C~+70°C),high humidity(95%non-condensing),and corrosive vapors(compatible with oil,gas,and chemicals).ATEX/IECEx Zone 2 certification allows deployment in hazardous areas like oil refineries and chemical reactors.

Advanced Fault Diagnostics:Real-time fault detection(open circuits,short circuits,overvoltage)triggers alerts via the DCS,enabling predictive maintenance and reducing unplanned downtime.Each channel features status LEDs(green for normal,red for fault)for quick visual troubleshooting—cutting diagnostic time by 60%compared to non-LED-equipped modules.

Seamless ABB Ecosystem Integration:As a native component of ABB’s AC 800M DCS,the module auto-detects and configures via Control Builder M software—no custom programming needed.It supports module chaining(up to 32 modules per bus)for scalable signal acquisition in large-scale projects(e.g.,multi-unit power plants).

Application Field

ABB AI880A 3BSE039293R1 is a versatile analog input module for process-critical industries.In power plants(fossil fuel and nuclear),it integrates with ABB AC 800M DCS to monitor key parameters:RTD inputs track turbine bearing temperatures(±0.1°C accuracy prevents overheating),while 4-20mA inputs measure steam pressure and generator output—ensuring compliance with NERC reliability standards.

In oil&gas production,the module is deployed in upstream drilling rigs and downstream refineries:It captures 4-20mA signals from flow meters(monitoring crude oil throughput)and thermocouple inputs from distillation columns(regulating refining temperatures).Its ATEX Zone 2 certification allows safe operation in hydrocarbon-rich environments.

In chemical processing,the module monitors reaction conditions:Configurable channels accept pH sensor signals(0-10V)and temperature inputs(Type K thermocouples)from reactors,enabling precise control of chemical reactions and preventing batch defects.Isolated inputs eliminate cross-talk between aggressive chemical process streams.

In water&wastewater treatment,the module processes signals from level sensors(4-20mA)in storage tanks and turbidity sensors(0-5V)in filtration systems.It communicates with ABB Symphony Plus DCS to automate pumping and dosing operations,ensuring compliance with EPA water quality standards and reducing manual intervention.

Related Products

ABB AC 800M DCS Controller:Central control unit that pairs with the AI880A module for large-scale process control and data integration.

ABB Control Builder M Software:Configuration tool for setting up input types,sampling rates,and fault thresholds for the AI880A module.

ABB HMI Panel 6AV2124-1JC01-0AX0:Human-machine interface for visualizing analog signal data(temperature,pressure)from the module.

ABB Shielded Signal Cable 3LNE080002R0001:Industrial-grade cable for noise-free transmission of analog signals from sensors to the module.

ABB 24V DC Power Supply 8PS320.100-2:Dedicated power module optimized for the AI880A’s voltage and current requirements.

ABB Terminal Block Kit 1SNA663002R1200:High-density,isolated terminal blocks for secure wiring of analog sensors to the module.

ABB DIN Rail Mounting Bracket 1SFA898101R1001:Hardware for installing the module in standard 35mm DIN rail control cabinets.

ABB Calibration Tool 3BHB008455R0001:Precision device for verifying the AI880A’s signal conversion accuracy and recalibrating channels.

Installation and Maintenance

Pre-installation preparation:Confirm compatibility with target ABB DCS(AC 800M,Symphony Plus).Gather tools:anti-static wristband,precision torque screwdriver(0.5-1.0 N·m),wire stripper,and laptop with Control Builder M software.Ensure the control cabinet is powered off and grounded to prevent electrostatic damage.Inspect the module for physical defects(e.g.,bent pins,cracked housing)and verify ATEX/IECEx certification if deploying in hazardous areas.

Installation steps:1.Mount the module on a 35mm DIN rail using the ABB 1SFA898101R1001 bracket—maintain 25mm clearance from heat-generating components(e.g.,power supplies)for airflow.2.Wire analog sensors to terminal blocks:Use shielded twisted-pair cables for all inputs;ground shields at the sensor end to prevent noise.Torque terminal screws to 0.8-1.0 N·m to avoid loose connections.3.Connect the 24V DC power supply to the module’s power terminals(verify polarity to prevent reverse damage).4.Establish DCS communication:Connect the PROFIBUS DP cable to the module’s bus port,then launch Control Builder M to detect the module and configure channel parameters(input type,sampling rate,alarm thresholds).5.Power on the system and run a calibration test:Use the ABB 3BHB008455R0001 tool to inject known signals;confirm the module’s output matches the input(within±0.01%full scale)and LEDs display normal status.

Maintenance recommendations:Conduct monthly inspections:Visually check terminal blocks for corrosion,loose wires,or insulation damage.Use compressed air(low-pressure)to remove dust from the module’s vents—avoid liquid cleaners.Every 6 months,perform a full calibration using the ABB calibration tool;recalibrate channels if deviations exceed±0.01%full scale.In case of fault LEDs(red),use Control Builder M’s diagnostic dashboard to identify issues(e.g.,open thermocouple,shorted current input)before replacing components.For hazardous area deployments,schedule annual ATEX/IECEx compliance checks to ensure sealing integrity.

Product Guarantee

ABB AI880A 3BSE039293R1 is backed by ABB’s industry-leading 24-month manufacturer’s warranty against material and workmanship defects.Each module undergoes rigorous testing:150,000-hour MTBF validation,temperature cycling(-25°C to+70°C),ESD/surge protection trials,and ATEX/IECEx hazardous area certification testing.ABB’s global technical support team provides 24/7 assistance for installation,configuration,and troubleshooting—with remote access to diagnose issues in real time.Extended warranty options(up to 5 years)and expedited delivery of replacement modules minimize downtime for critical process control systems.As a genuine ABB component,it ensures seamless integration with ABB’s automation ecosystem—backed by over 130 years of industrial technology expertise.

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