Product Description

Brand:​ABB

Model:​216DB61(HESG324063R100/H)

Series:​Advant/ABB Ability™S800 I/O

Channels:​32 Isolated Digital Inputs

Input Voltage:​24 VDC(Sink/Source)

The ABB 216DB61 HESG324063R100/H​is a high-density 32-channel digital input module​from ABB’s renowned S800 I/O​family,designed for the Advant​and ABB Ability™800xA​control systems.This module provides reliable interfacing for dry contacts and proximity switches,converting field device status signals into digital data for the control system.With advanced diagnostics and flexible sinking/sourcing configuration,it ensures robust performance in demanding industrial applications.Genuine ABB product,fully tested and guaranteed.

Application Scenarios

In a automotive manufacturing paint shop,hundreds of pneumatic valves control the precise movement of paint applicators.Each valve’s position is verified by a limit switch,ensuring the painting robots operate correctly.The ABB 216DB61​module is deployed in a remote I/O cabinet near the production line,monitoring all 32 limit switches on a section of the painting system.When a robot completes a movement,the corresponding limit switch activates,sending a 24VDC signal to the 216DB61.The module immediately transmits this status change to the central ABB Advant​controller via the high-speed S800 I/O​bus.This real-time feedback allows the system to confirm each mechanical action before proceeding to the next step in the painting sequence.The high channel density of the 216DB61​reduces the number of modules needed,saving panel space and wiring costs.Its robust design withstands the electrical noise typical in industrial environments,ensuring reliable operation critical to maintaining production throughput and quality.

Key Parameters

Parameter

Value/Description

Product Model​

216DB61(HESG324063R100/H)​

Manufacturer​

ABB

Product Type​

Digital Input Module

System Compatibility​

Advant OCS,ABB Ability™800xA with S800 I/O

Number of Channels​

32

Input Voltage​

24 VDC(Nominal)

Input Type​

Sink/Source(Configurable per channel)

On-state Voltage Range​

11 VDC to 30 VDC

Off-state Voltage Max​

5 VDC

Input Delay​

Typically 1-3 ms(filterable)

Isolation​

Channel-to-channel and channel-to-bus

Power Consumption​

Typical 1.5W from internal 5V bus

Connection​

Removable terminal block

Technical Principles and Innovative Values

The ABB 216DB61​exemplifies ABB’s engineering philosophy of combining high density with exceptional reliability and diagnostic capabilities in industrial I/O.

High-Density,Flexible Configuration:​The module’s 32-channel design maximizes I/O point count per module,significantly reducing the footprint in control cabinets.A key innovation is its support for both sinking​and sourcing​input types on a per-channel basis.This flexibility simplifies inventory and allows the same module to be used with different field device technologies without hardware changes,configured via software.

Advanced Diagnostics and Signal Conditioning:​Each input channel includes advanced signal filtering to reject electrical noise common in industrial environments,preventing false triggers.The module provides detailed diagnostic information to the control system,identifying issues like wire breaks or field power loss on a per-channel basis.This enables predictive maintenance,as operators can be alerted to deteriorating field devices before they cause a fault.

Robust Isolation and Hot-Swapping Capability:​The 216DB61​features optical isolation between each channel and the internal logic,and between the field side and the system bus.This prevents faults in one channel or external voltage surges from affecting the entire module or the control system.When used in a redundant system configuration,it supports hot-swapping,allowing for module replacement without shutting down the process,which is critical for high-availability applications.

Application Cases and Industry Value

Case Study:Packaging Line Upgrade in Food&Beverage

A major food processing plant experienced frequent unplanned downtime on its high-speed bottling line due to faulty limit switch readings.The existing digital input cards had poor noise immunity and limited diagnostics.The plant upgraded to an ABB Advant​system utilizing the 216DB61​modules in distributed I/O panels along the line.

The 216DB61​modules were configured to monitor the status of fill-level sensors,cap presence sensors,and conveyor belt alignment switches.The improved noise immunity immediately eliminated the false trips that had plagued the old system.Furthermore,when a sensor on a capping machine began to fail intermittently,the diagnostic capabilities of the 216DB61​logged the signal fluctuations.Maintenance was alerted through the system’s asset management software and replaced the sensor during a planned break,avoiding a line stoppage that would have cost thousands of dollars in lost production.The project demonstrated a clear return on investment through increased Overall Equipment Effectiveness(OEE).

Related Product Combination Solutions

The 216DB61​operates as part of a comprehensive control system.Key related components include:

S800 Base Units​(e.g.,SA801):The physical mounting unit that houses the 216DB61​and provides the connection to the fieldbus.

S800 Power Supplies​(e.g.,SD822):Provide the necessary power for the I/O modules and the field devices.

S800 Digital Output Modules​(e.g.,216DB62):Often used in the same base unit to control actuators like solenoid valves and motor starters.

S800 Analog Modules​(e.g.,216EA61​AI module):For applications requiring measurement of process variables like temperature or pressure.

ABB AC 800M Controller​(e.g.,PM864):The high-level controller that processes the input data from the 216DB61​and executes the control logic.

CI854 Communication Interface:A module that allows the S800 I/O station to communicate over Profibus DP with the main controller.

Installation,Maintenance,and Full-Cycle Support

Installation involves slotting the 216DB61​into an appropriate S800 base unit and securing the removable terminal block.Field wiring is connected to this terminal block.Configuration is performed using ABB’s Control Builder engineering software,where the module is added to the hardware configuration tree,and parameters like filter times are set.

Routine maintenance is minimal but should include periodic checks of the module’s status LEDs.The”OK”LED should be steadily green,indicating normal operation.If a”Module Fault”LED is lit,the engineering station software provides detailed diagnostic information.For replacement,it is critical to have a backup of the configuration.The module can be replaced by powering down the station(or performing a hot-swap in redundant systems),swapping the hardware,and ensuring the new module adopts the correct configuration.

We guarantee that every ABB 216DB61 HESG324063R100/H​module we supply is 100%genuine,sourced from authorized channels,and undergoes full functional testing prior to shipment.We provide a 12-month warranty and expert technical support to assist with integration.

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