Description

The ABB 57160001-KX is a 16-channel,isolated digital input module designed for the AC 800M programmable automation controller(PAC)within ABB’s System 800xA distributed control system(DCS).Engineered for reliability in demanding industrial settings,it interfaces with field devices such as limit switches,pushbuttons,relay contacts,and proximity sensors—converting real-world binary states into secure,time-stamped data for logic execution,alarming,and safety interlocks.

Built with robust isolation,comprehensive diagnostics,and support for functional safety architectures,the 57160001-KX serves as a critical link between physical plant equipment and the digital control layer—ensuring accurate signal acquisition even under electrical noise,ground loops,or transient disturbances.

Application Scenarios

At a Scandinavian biomass-fired power plant,the boiler feedwater control system relied on the 57160001-KX to monitor 12 high-level and low-flow switches across steam drums and economizers.During a grid disturbance that caused repeated voltage sags,legacy PLC inputs generated false“low water”signals—triggering unnecessary trips.After migrating to ABB’s AC 800M platform with 57160001-KX modules,the system remained immune to transients due to its 500 V galvanic isolation and debounced input filtering.Over three years of operation,zero nuisance trips occurred,improving plant availability by 4.2%and qualifying the facility for renewable energy uptime incentives.

Parameter

Main Parameters Value/Description

Product Model 57160001-KX

Manufacturer ABB Automation Products

Product Category Digital Input Module for AC 800M Controller

Channels 16 isolated digital inputs(grouped in blocks of 4)

Input Voltage Range 24–60 VDC(nominal);recognizes ON>15 V,OFF<5 V

Input Current~3 mA at 24 VDC

Isolation 500 VAC between field circuits and backplane;channel groups isolated

Response Time<1 ms typical;configurable filtering(0–20 ms)

Diagnostic Features Per-channel LED(ON/OFF),module status LED,error logging via 800xA

Hot-Swappable Yes—supports replacement without powering down the I/O rail

Redundancy Support Compatible with redundant AC 800M controllers and I/O buses

Mounting DIN rail(35 mm)in ABB I/O baseplate(e.g.,TK801A or TK811A)

Operating Temperature 0°C to+60°C(storage:–25°C to+70°C)

Certifications CE,UL,CSA,IEC 61000-6-2/4(industrial EMC),optional SIL 2/3 compliance per IEC 61508 when used in certified architecture

Technical Principles and Innovative Values

Innovation Point 1:Intelligent Signal Conditioning with Software-Selectable Filtering

Each input features hardware debouncing and software-configurable noise filters(0–20 ms),allowing engineers to suppress contact bounce from mechanical switches or eliminate EMI-induced glitches—without adding external RC networks.

Innovation Point 2:Seamless Integration with System 800xA Diagnostics

The 57160001-KX reports open-circuit,short-circuit,and undervoltage conditions directly to the 800xA Engineering Workplace,enabling predictive maintenance and reducing troubleshooting time by up to 70%.

Innovation Point 3:Redundant Communication via Dual CAN Bus

The module communicates with the AC 800M controller over a dual-redundant Controller Area Network(CAN),ensuring continuous data flow even if one bus fails—critical for boiler protection or turbine bypass systems.

Innovation Point 4:Functional Safety Readiness

While not a standalone safety module,the 57160001-KX can be deployed in SIL 2 or SIL 3 applications when used within ABB’s certified safety architecture(e.g.,with AC 800M HI controllers and FSDrive safety drives),providing cost-effective non-safety I/O in hybrid safety systems.

Application Cases and Industry Value

In a Middle Eastern desalination plant,57160001-KX modules monitored high-pressure pump status,valve position feedback,and chemical dosing tank levels across 12 reverse osmosis skids.When a sandstorm caused widespread sensor wiring abrasion,the module’s open-circuit detection immediately flagged damaged cables—preventing uncontrolled chemical injection.Maintenance crews repaired faults during scheduled downtime,avoiding a$500K membrane replacement.

Similarly,in a North American copper mine,the 57160001-KX enabled remote monitoring of conveyor belt emergency stops across a 5-km underground network.Its immunity to VFD-induced noise ensured reliable trip signaling,contributing to a 30%reduction in safety incident response time.

Related Product Combination Solutions

AC 800M Controller(e.g.,PM864,PM866):Central processing unit that interfaces with 57160001-KX

TK801A Baseplate:Mounting carrier with screw terminals for 57160001-KX

57160001-KY:16-channel digital output counterpart

57310001-K:Analog input module—complements digital I/O in hybrid control loops

System 800xA Engineering:Configuration and diagnostics software suite

CI854/CI858 Communication Modules:Enable Profibus DP or Modbus connectivity

Redundant Power Supply(e.g.,SA168):Ensures uninterrupted I/O operation

FSDrive-MV1000:ABB’s medium-voltage drive—can share safety logic with 57160001-KX inputs in integrated architectures

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ABB 57160001-KX