ABB 086339-001 | Hot-swap capable analog input module for power, oil & gas, and pharma applications

Description

Application Scenarios:

At a U.S. LNG export terminal upgrading its flare gas monitoring system, engineers needed to integrate over 200 legacy and smart transmitters—measuring pressure, temperature, and flow—across hazardous zones. Space in existing marshalling cabinets was extremely limited, and regulatory compliance required SIL2-capable hardware. The ABB 086339-001 became the ideal solution: its 16-channel density reduced module count by 40% compared to older 8-channel cards, while its universal input capability eliminated the need for separate RTD or mA-specific modules. During commissioning, the built-in open-wire detection flagged a broken thermocouple in a cryogenic line before cooldown—a fault that would have gone unnoticed with basic AI cards. Simultaneously, the HART overlay allowed technicians to remotely configure transmitter damping and verify calibration without climbing 30-meter platforms. The result: faster startup, enhanced safety, and full compliance with IEC 61511.

Parameter:

Main Parameters Value/Description

Product Model **086339-001 **(3BSE022452R1)

Manufacturer ABB

Product Category Analog Input (AI) Module / S800 I/O Module

Number of Channels 16 (individually configurable)

Input Signal Types • 4–20 mA (with HART)

• 0–20 mA / 0–24 mA

• 0–5 V / 0–10 V

• RTD (Pt100. Pt1000. Ni100. etc.)

• Thermocouple (J, K, T, E, N, R, S, B)

Accuracy ±0.05% of full scale (for mA/V); ±0.1°C (for RTD/TC, typical)

HART Support Yes—built-in HART multiplexer; supports simultaneous communication on all channels

Electrical Isolation 500 VAC between field and backplane; channel-to-channel isolation via design

Diagnostic Features Per-channel open-wire detection, sensor short-circuit alert, HART device status, out-of-range warning

Sampling Rate Up to 20 samples/sec per channel (configurable)

Power Consumption Approx. 3.8 W (from I/O backplane)

Operating Temperature 0°C to +60°C

Certifications CE, UL, CSA, IEC 61508 SIL2

Technical Principles and Innovative Values:

• True Universal Input: Each of the 16 channels can be independently configured for any supported signal type—eliminating inventory complexity and enabling flexible field device integration.

• Integrated HART Multiplexer: Unlike external HART modems, the 086339-001 handles HART communication natively, allowing real-time access to smart transmitter diagnostics, configuration, and secondary variables—all within System 800xA.

• SIL2-Certified Architecture: Designed and validated per IEC 61508. it can be deployed in safety instrumented systems (SIS) up to SIL2. ensuring fail-safe behavior under fault conditions.

• Advanced Diagnostics: Detects open sensors, short circuits, and signal degradation in real time—enabling predictive maintenance and reducing unplanned shutdowns.

• High Density Without Compromise: 16 high-accuracy channels in a single module width reduce cabinet footprint while maintaining performance suitable for custody transfer or reactor control.

Application Cases and Industry Value:

In a European biopharma cleanroom producing mRNA vaccines, precise temperature uniformity across lyophilizers is critical for product stability. The facility deployed ABB 086339-001 modules to read 192 RTD sensors across 12 freeze-dryers. The ±0.1°C accuracy ensured shelf temperature stayed within ±0.5°C of setpoint—meeting stringent FDA requirements. During routine HART polling, one module detected a drifting RTD calibration trend; the sensor was replaced during scheduled maintenance, avoiding a potential batch rejection valued at €4.7 million. Over two years, the plant achieved zero temperature-related deviations, attributing much of this success to the reliability and intelligence of the 086339-001.

Related Product Combination Solutions:

• ABB TB511A: S800 I/O baseplate—provides power, communication, and hot-swap support for 086339-001.

• ABB PM866: Redundant AC 800M CPU—processes high-fidelity AI data for advanced control and safety logic.

• ABB 086351-004: 32-channel digital input module—for hybrid systems requiring both analog and discrete signal acquisition.

• ABB AFC094AE02: 16-channel analog output module—complements 086339-001 in closed-loop control strategies.

• ABB IMRIO02: Redundant I/O interface—ensures continuous AI data flow during network or controller switchover.

• ABB AI810: Legacy S800 AI module—086339-001 is its higher-density, HART-enabled successor.

• ABB CI858: Profibus DP/V1 communication module—for remote I/O stations housing 086339-001 in large plants.

• ABB System 800xA Asset Optimizer: Leverages HART and diagnostic data from 086339-001 for predictive maintenance and performance analytics.

Installation, Maintenance, and Full-Cycle Support:

Installing the ABB 086339-001 is straightforward: insert it into an S800 baseplate (e.g., TB511A), connect field wiring to the removable spring-clamp terminal block, and configure each channel type in Control Builder M. No jumpers or DIP switches are required—configuration is fully software-defined.

Maintenance is proactive: System 800xA continuously monitors sensor health and HART device status. Open-wire or calibration drift alerts trigger work orders before process impact occurs. Calibration intervals are extended thanks to factory-trimmed accuracy and long-term stability.

We supply only genuine 086339-001 3BSE022452R1 units—each validated for signal accuracy, HART functionality, and diagnostic integrity on live S800 test benches. Every module includes original labeling, traceable serial numbers, and a 12-month warranty. Our technical team provides signal wiring diagrams, HART integration guides, and SIL2 compliance documentation. Contact us for a customized solution—because in precision measurement, every millivolt tells a story.