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Description
Application Scenarios
At a coal-fired power plant in Poland undergoing DCS modernization, over 2.000 boiler safety interlock signals (flame detectors, fan status, valve limits) needed reliable monitoring. Using DATX100 bases with DI885 (32-channel, 24 V DC, high-speed) modules allowed engineers to:
Reduce I/O cabinet count by 35% vs. 16-channel alternatives
Perform module replacements without de-energizing field wiring (thanks to pluggable electronics)
Use standardized wiring templates across all turbine and boiler panels
During commissioning, a faulty DI885 was swapped in under 90 seconds—while the plant remained online—demonstrating the DATX100’s critical role in high-availability infrastructure.
Technical Principles and Innovative Values
Innovation Point 1: True Modular I/O Architecture
Separation of field wiring (DATX100) from electronics (DI88x) means field cables never need re-termination during module upgrades or failures—cutting MTTR (Mean Time To Repair) by up to 80%.
Innovation Point 2: Ultra-High Density
32 channels in a 40 mm wide module delivers 0.8 channels/mm—among the highest densities in the S800 portfolio—critical for space-constrained control rooms.
Innovation Point 3: Universal Compatibility
The same DATX100 base supports standard, high-speed, and SIL 3-certified fail-safe digital input modules—enabling mixed-safety-level systems in a single chassis.
Innovation Point 4: Future-Proof Investment
Existing DATX100 wiring remains valid when upgrading from DI880 to DI885 or FSDI142—protecting installation labor costs during technology refreshes.
Application Cases and Industry Value
In a Canadian oil sands extraction facility, 144 DATX100 bases with DI885 modules monitor conveyor belt alignment, pump run status, and emergency stop circuits across a 3-km processing line. The <1 ms response time of the DI885/DATX100 combo ensured rapid shutdown during a belt tear incident—preventing $ 4M in potential damage. Maintenance teams praised the ability to test and replace modules using live mimic diagrams in System 800xA, with zero wiring errors over 5 years.
Similarly, in a German waste-to-energy plant, DATX100 + FSDI142 pairs handle all burner management safety inputs. The passive base’s robust terminals withstood repeated thermal cycling (-20°C winter to +60°C summer), while the fail-safe module met EN 62061 SIL 3 requirements—validating the architecture for life-critical combustion control.
Related Product Combination Solutions
DI880: Standard 32-channel digital input (10 ms filter)
DI885: High-speed 32-channel digital input (<1 ms, for pulse counting or fast interlocks)
FSDI142: 16-channel fail-safe digital input (SIL 3 per IEC 61508/62061)
TB850: Local I/O baseplate with HART and redundancy support
TB870: Redundant controller baseplate for UFC770 CPUs
3BHE019719R0101 (PFSK152): 10 A redundant power supply for stable 24 V DC
CI854A: PROFIBUS DP communication interface
DATX200: 16-channel version for mixed analog/digital racks
This ecosystem enables scalable, maintainable, and safety-compliant discrete signal handling from basic monitoring to certified safety functions.
Installation, Maintenance, and Full-Cycle Support
Installation:
Mount DATX100 on DIN rail within TB8xx baseplate
Terminate all 32 field wires to labeled screw terminals (clear channel ID legend)
Insert compatible electronic module (e.g., DI885) until it clicks into place
Maintenance:
To replace: Lift module latch → pull out module → insert new one
Field wiring remains untouched—no electrician required for module swap
Diagnostics visible via LEDs on the electronic module and System 800xA
We supply 3ASC25H208 (DATX100) units as new, factory-sealed, with full mechanical integrity testing:
Terminal torque validation (0.5–0.6 Nm)
Vibration resistance (IEC 60068-2-6)
Thermal cycling (-25°C ↔ +70°C x 10 cycles)
All units include a 12-month warranty and are fully compatible with ABB’s latest Control Builder M and System 800xA releases.
Contact us for bulk pricing, pre-wired panel solutions, or compatibility verification with your existing S800 I/O strategy. Whether you’re building a new power plant control system or expanding a mining automation network, the ABB DATX100 (3ASC25H208) delivers unmatched serviceability, density, and lifecycle value for digital input applications.
