Description

The HONEYWELL CC-PAIH01 (Part Number: 51405038-175) is a field termination assembly (FTA)—also known as a terminal block module—designed specifically for 8-channel analog input (AI) modules in Honeywell’s Experion PKS FTEB and legacy HLAI I/O systems. It provides a safe, organized, and serviceable interface between field instruments (e.g., pressure transmitters, RTDs, flow meters) and high-density AI cards such as the TK-MAP081 or 51195066-100. Featuring fused inputs, optional surge suppression, and clear channel labeling, the CC-PAIH01 ensures signal integrity while simplifying installation, troubleshooting, and maintenance.

Application Scenarios

At a Middle Eastern gas processing plant, recurring drift in compressor discharge pressure readings was traced to intermittent field wiring faults exacerbated by vibration and heat. Technicians struggled with crowded terminal strips and no overcurrent protection—leading to damaged I/O cards during short circuits. After standardizing on the HONEYWELL CC-PAIH01 (51405038-175) across all new AI racks, each 4–20 mA loop gained individual fuse protection and secure screw terminals rated for 2.5 mm² wire. During a lightning storm, a nearby strike induced a transient that blew two fuses—but the AI modules remained unharmed. Technicians replaced the fuses in minutes using the clearly labeled, front-access design. Since deployment, I/O card failures dropped by 90%. For instrument teams, the CC-PAIH01 turned field wiring from a vulnerability into a robust, maintainable layer.

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Note: The CC-PAIH01 does not process signals—it is a passive, protective wiring interface. Signal conditioning occurs in the I/O module.

Technical Principles and Innovative Values

Innovation Point 1: Modular, Serviceable Fuse Architecture

Each channel on the CC-PAIH01 has an easily accessible, field-replaceable fuse. Unlike older FTAs with soldered links or shared protection, this design isolates faults without affecting adjacent loops—minimizing downtime and protecting expensive I/O cards.

Innovation Point 2: Precision Mechanical Alignment

The CC-PAIH01 features alignment pins and a keyed connector that ensure perfect mating with the FTEB backplane-mounted AI module. This eliminates miswiring during maintenance—a common cause of cross-channel errors in dense cabinets.

Innovation Point 3: HART Signal Integrity Preservation

With low-capacitance, shielded internal routing and minimal stub lengths, the CC-PAIH01 maintains HART communication fidelity from field device to I/O card—critical for asset management via AMS or Experion Device Manager.

Innovation Point 4: Brownfield Migration Enabler

The CC-PAIH01 fits both modern FTEB racks and legacy HLAI cabinets, allowing plants to upgrade I/O electronics while reusing existing field wiring terminations—cutting retrofit labor by up to 50%.

Application Cases and Industry Value

During a control system upgrade at a European pulp & paper mill, engineers needed to replace aging analog cards without disturbing thousands of field wires. They installed new 51195066-100 AI modules into FTEB chassis and mated them with CC-PAIH01 (51405038-175) FTAs pre-wired to the original field cables. The modular design allowed one technician to verify and transfer 8 channels in under 15 minutes per rack. Post-commissioning, HART diagnostics revealed three failing pH transmitters that had been masked by analog-only monitoring. The project finished 3 weeks ahead of schedule, with zero wiring-induced faults. The CC-PAIH01 proved that the “last inch” of the signal chain matters just as much as the I/O card itself.

Related Product Combination Solutions

Honeywell TK-MAP081: 8-channel analog input module—native partner for CC-PAIH01

Honeywell 51195066-100: 16-channel AI card—use two CC-PAIH01 units per module

Honeywell FTEB Chassis (e.g., DC-TFB402): Host platform that accepts CC-PAIH01 via backplane

Honeywell 51405038-200 Series: Surge suppression add-on modules for CC-PAIH01 (e.g., for outdoor panels)

Emerson AMS Suite: Leverages clean HART signals passed through CC-PAIH01 for predictive maintenance

Phoenix Contact COMBI series: Alternative terminal blocks—but lack Honeywell-specific alignment and fuse integration

Honeywell HLAI System: Legacy architecture fully compatible with CC-PAIH01 for life-extension projects

This ecosystem ensures that every milliamp from the field arrives at the controller accurately, safely, and reliably.

Installation, Maintenance, and Full-Cycle Support

Installation of the CC-PAIH01 (51405038-175) begins with DIN rail mounting directly below or adjacent to the FTEB/HLAI chassis. Field wires are terminated to labeled screw terminals, with shield grounded at the FTA. The module then snaps onto the backplane connector of the AI card—no tools required. Fuses are pre-installed but can be upgraded for specific applications (e.g., higher inrush tolerance).

Maintenance is highly efficient: if a channel fails, technicians first check the corresponding fuse (visible through a window). If blown, it’s replaced in seconds using a standard fuse puller. The entire FTA can be de-mated from the I/O card without disconnecting field wires—ideal for card replacement or calibration.

Every HONEYWELL CC-PAIH01 / 51405038-175 we supply is factory-inspected for mechanical integrity, fuse continuity, and terminal torque. Units include compatibility verification for your I/O module type and are backed by expert technical support. Whether you’re building a new system, expanding capacity, or replacing damaged FTAs, we ensure seamless integration and long-term reliability.