Description

The ABB IMASI02 is a redundant analog input interface module designed for ABB’s AC 800M and Symphony Plus distributed control systems (DCS). As a passive, high-availability I/O base unit, it enables dual-redundant connection of field sensors (e.g., 4–20 mA transmitters) to two independent I/O modules, ensuring continuous signal acquisition even during hardware failure—critical for power generation, oil & gas, and chemical processes.

Application Scenarios

At a combined-cycle power plant in Texas, turbine bearing temperature monitoring was causing unexpected trips due to single-point I/O failures. Engineers upgraded the system using the ABB IMASI02. wiring each RTD transmitter to a single IMASI02 base that split the signal to two redundant AI810 modules in separate AC 800M racks. When one I/O card later failed during a heatwave, the backup seamlessly took over—preventing a $ 2M/hour outage. The IMASI02’s passive redundancy architecture proved essential not just for reliability, but for regulatory compliance in critical machinery protection.

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Technical Principles and Innovative Values

Innovation Point 1: Passive Redundancy Without Active Electronics

The IMASI02 contains no active components—just precision signal-splitting circuitry. This eliminates a potential failure point, making redundancy truly fail-safe and maintenance-free over decades.

Innovation Point 2: Single Field Wire, Dual System Paths

Field instruments connect only once to the IMASI02. which then splits the signal to two physically separate I/O modules. This reduces wiring errors, saves terminal space, and cuts installation labor by 50%.

Innovation Point 3: Seamless Integration with AC 800M Redundancy Logic

In Control Builder M, the redundant AI channels are logically grouped. The controller automatically selects the healthy signal—no custom code required.

Innovation Point 4: Diagnostic Transparency

While passive, the IMASI02 supports continuity checks via the I/O modules. Combined with ABB 800xA Asset Optimization, it enables predictive maintenance on sensor loops.

Application Cases and Industry Value

In a European LNG regasification terminal, custody transfer flow meters required SIL2-compliant signal acquisition. The engineering team deployed ABB IMASI02 bases paired with dual AI810 modules to feed both the BPCS and SIS systems from a single 4–20 mA transmitter loop. Over five years, the system achieved 99.999% availability, with zero spurious trips traced to I/O failure. Auditors specifically cited the IMASI02’s clean signal separation as a best practice in functional safety design.

Related Product Combination Solutions

ABB AI810: 16-channel analog input module—primary partner for IMASI02 in AC 800M systems

ABB AI820: HART-enabled AI module—adds device diagnostics when used with IMASI02

ABB AC 800M PM864A: Controller CPU—supports redundant I/O configuration with IMASI02

ABB 800xA System 800: Integrated DCS platform—provides unified engineering and alarm management for IMASI02-based signals

ABB Symphony Plus INAI01: Legacy analog input card—compatible with IMASI02 in hybrid modernization projects

ABB TB840: Terminal base for non-redundant AI—contrast solution where redundancy isn’t required

ABB CI854A: Communication interface—enables remote IMASI02 racks via Profibus DP

ABB Asset Optimize: Predictive maintenance suite—uses IMASI02 loop data for transmitter health scoring

Installation, Maintenance, and Full-Cycle Support

Installing the ABB IMASI02 is straightforward: mount it on a DIN rail, connect field wires to its spring-clamp terminals, and plug two identical I/O modules (e.g., AI810) into its top connectors. No power or configuration is needed—the redundancy is purely physical. During maintenance, either I/O module can be hot-swapped without disturbing field wiring or process operation.

For optimal performance, use twisted-pair shielded cables and ground shields at the cabinet entry point. Avoid routing signal wires parallel to power cables to minimize noise—especially critical for low-level RTD signals.

We supply genuine IMASI02 units (typically order code 3BSE013245R1) that are factory-tested for contact resistance, insulation integrity, and mechanical fit. Each unit includes channel labeling strips and complies with ABB’s long-term support policy for AC 800M infrastructure. Backed by a 12-month warranty and expert application engineering, our IMASI02 modules ensure your critical analog signals never go silent.

Contact us for a customized solution—including redundancy architecture review, compatibility verification, or global logistics for multi-site DCS upgrades. Keep your process visible, even when hardware fails.