Description

The 216EA61B HESG448230R1/G is a 16-channel digital input(DI)module from ABB’s AC 800M controller family,designed for use in the System 800xA distributed control system(DCS).This ruggedized I/O interface converts field discrete signals—such as switch statuses,relay contacts,or proximity sensor outputs—into reliable logic-level data for process automation and safety monitoring.

Application Scenarios

At a combined-cycle power plant in Germany,frequent false alarms from turbine auxiliary status signals were causing unnecessary load shedding.Investigation traced the issue to aging DI cards with poor noise immunity.After replacing them with ABB 216EA61B HESG448230R1/G,the plant eliminated spurious inputs thanks to its opto-isolated channels and built-in signal filtering.Each of the 16 inputs now reliably reports valve position,pump run status,and breaker state—even during high-voltage switching transients.The 216EA61B HESG448230R1/G’s per-channel LED indicators also slashed troubleshooting time from hours to minutes during scheduled outages,directly improving operational availability.

Parameter

Main Parameters Value/Description

Product Model 216EA61B HESG448230R1/G

Manufacturer ABB

Product Category 16-channel digital input module(sink type)

Input Type 24 VDC,sink configuration(NPN-compatible)

Number of Channels 16,individually isolated

Input Voltage Range 15–30 VDC(ON),<5 VDC(OFF)

Input Current~7 mA per channel at 24 VDC

Isolation 500 VAC between field and backplane(channel-to-system)

Response Time<10 ms(configurable via Control Builder M)

Diagnostics Per-channel LED status+system-level fault reporting

Operating Temperature 0°C to+60°C(IEC 60068-2 compliant)

Mounting DIN rail in ABB I/O baseplate(e.g.,TB840A),hot-swap capable

Note:“Sink”input design means the module completes the circuit to ground—ideal for interfacing with PNP sensors or dry contacts via external pull-up resistors.

Technical Principles and Innovative Values

Innovation Point 1:True galvanic isolation per channel prevents ground loops and protects the AC 800M controller from field-side surges—critical in environments with large motors or switchgear.

Innovation Point 2:Integrated diagnostic LEDs provide immediate visual feedback for each input state(green=active,off=inactive),enabling rapid on-site verification without probing or software access.

Innovation Point 3:Seamless integration with ABB’s Control Builder M engineering suite allows online configuration of debounce filters,alarm thresholds,and tag names—reducing commissioning errors.

Innovation Point 4:Designed for long-term compatibility;the 216EA61B HESG448230R1/G works across multiple AC 800M hardware generations(PM86x CPUs)and System 800xA versions(v5.x to v6.x).

Innovation Point 5:Supports partial stroke testing and maintenance bypass modes when used in safety-related applications,contributing to compliance with IEC 61511(SIL 2 achievable with proper architecture).

Application Cases and Industry Value

In a pulp&paper mill in Sweden,the 216EA61B HESG448230R1/G was deployed across 12 dryer sections to monitor steam valve limit switches and bearing vibration alarms.Previously,moisture ingress in junction boxes caused intermittent signals that triggered false shutdowns.The module’s robust 24 VDC threshold and noise rejection ensured stable operation despite EMI from nearby drives.Over two years,unplanned stops dropped by 65%,and maintenance teams leveraged the clear LED indicators to validate sensor health during weekly rounds—turning reactive fixes into proactive care.The plant later reused the same I/O strategy in its new biomass boiler,citing the 216EA61B HESG448230R1/G as a“proven workhorse.”

Related Product Combination Solutions

ABB 216EA62B HESG448231R1/G:16-channel digital output(DO)counterpart for actuator control

ABB 216SA61 HESG448330R1:Analog input module(8-channel,4–20 mA)for temperature/pressure signals

ABB TB840A:Standard I/O baseplate with screw terminals for 216EA61B HESG448230R1/G

ABB PM864A:AC 800M CPU controller commonly paired with this DI module

ABB CI854A:PROFIBUS DP communication module for remote I/O expansion

ABB 216EA61B-RMA:Refurbished unit with full functional test and calibration certificate

ABB Control Builder M:Official configuration and diagnostics software

ABB TK801A:Ethernet communication kit for AC 800M connectivity

These components form a scalable,interoperable I/O layer—ideal for both greenfield DCS deployments and legacy System 800xA upgrades.

Installation,Maintenance,and Full-Cycle Support

Installation of the 216EA61B HESG448230R1/G begins with mounting it onto an ABB-approved baseplate(e.g.,TB840A)in a properly grounded cabinet.Field wiring uses standard 1.5 mm²stranded conductors with shield grounded at one end.No jumpers or DIP switches are required—channel behavior is defined entirely in Control Builder M,including input filtering to suppress contact bounce.The module supports hot insertion,allowing replacement during live operation without disrupting adjacent I/O or controller logic.

For maintenance,the front-facing LEDs eliminate guesswork:a steady green light confirms a valid ON signal,while flickering may indicate a failing field device.Comprehensive diagnostics are also available via System 800xA’s asset portal,showing input counters,last state change,and error logs.Every 216EA61B HESG448230R1/G we supply undergoes 100%functional validation—including simulated wetting current tests and isolation withstand checks—and includes firmware version verification for your specific AC 800M setup.We offer a 12-month warranty,technical datasheets,and support from engineers with hands-on System 800xA migration experience.

Contact us for a customized solution—whether you’re expanding your DCS I/O capacity,replacing obsolete modules,or securing critical spares for continuous-operation facilities.With rigorous testing and deep ABB ecosystem knowledge,we ensure your automation infrastructure remains resilient,compliant,and efficient.

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