ABB AI835 Thermocouple/mV Input Module (S800 Series I/O) (XIONGBA)

ABB AI835 Thermocouple/mV Input Module (S800 Series I/O) (XIONGBA)

Brand Model: ABB AI835
Product Name: Thermocouple/mV Input Module (S800 Series I/O)
Warranty: 1 year
Size: 102 mm (height) x 45 mm (width) x 119 mm (depth)
Weight: 0.24 kg
Origin: Sweden
Inventory: Available (contact local distributors for stock levels)
Delivery Time: 3–5 business days for standard models; 3–5 weeks for custom configurations

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Description

The ABB AI835 is a specialized analog input module designed for high-precision thermocouple (TC) and millivolt (mV) signal acquisition in industrial automation systems. Engineered for harsh environments, it integrates seamlessly with ABB’s Symphony Plus and 800xA distributed control systems (DCS), making it ideal for applications requiring real-time temperature monitoring and process control. Below is a comprehensive overview based on verified technical insights and industry context:

Product Overview

The ABB AI835 (Hardware ID: AI835, Order Code: 3BSE008520R1) is part of ABB’s S800 Series I/O platform, supporting 8 differential input channels for thermocouple or mV measurements. Each channel can be individually configured for TC types B, C, E, J, K, N, R, S, T or linear mV ranges (-30 mV to +75 mV) 19. Channel 8 can be designated as a cold junction (CJ) compensation channel, either via a local 4-wire Pt100 RTD or a user-defined fixed temperature 19. This modular design ensures flexibility in temperature measurement applications across industries like power generation, oil & gas, and chemical processing.

 

Key features include 15-bit resolution (A/D conversion), 50 V galvanic isolation, and IP20-rated protection against dust and accidental contact 112. The module supports hot-swappable installation and interfaces with ABB’s TU810/TU830 terminal units for power distribution and signal termination 914.

Technical Specifications

Parameter Name Parameter Value
Product Model ABB AI835 (3BSE008520R1)
Manufacturer ABB
Product Type Thermocouple/mV Input Module (S800 Series I/O)
Input Channels 8 differential (TC/mV), Channel 8 configurable for cold junction compensation
Resolution 15-bit
Accuracy ±0.1% of full-scale range (FSR)
Input Ranges -30 mV to +75 mV (linear) or TC types B, C, E, J, K, N, R, S, T
Cold Junction Compensation Local 4-wire Pt100 RTD or fixed temperature input
Isolation 50 V galvanic isolation (field to logic)
Power Supply 24 VDC ±10% (40 mA typical, 76 mA max)
Operating Temperature -25°C to +70°C
Storage Temperature -40°C to +85°C
Dimensions 102 mm (height) x 45 mm (width) x 119 mm (depth)
Weight 0.24 kg
Environmental Compliance IP20, IEC 61000-6-4 (EMC), ISA-S71.04 G3
Safety Certification CE, UL 508, RoHS
Mounting 35 mm DIN rail (horizontal/vertical orientation)

Key Features and Advantages

Precision Temperature Measurement:

 

  • 15-bit resolution ensures accurate conversion of thermocouple signals, critical for applications like boiler temperature control in power plants .
  • Automatic cold junction compensation eliminates manual adjustments, reducing setup time and errors.
  • Open circuit detection (≤5 seconds) and noise rejection (-70 dB normal mode, -90 dB common mode) enhance signal integrity in noisy environments 8.

 

Flexible Configuration:

 

  • 8 independent channels support mixed thermocouple types and mV signals in the same module, minimizing hardware complexity 9.
  • Hot-swappable design allows module replacement without disrupting operations, improving system uptime 14.
  • Multi-protocol compatibility (PROFIBUS DP, Modbus RTU) enables integration with third-party PLCs and SCADA systems 7.

 

Robust Industrial Design:

 

  • Wide temperature range (-25°C to +70°C) and ISA-S71.04 G3 corrosion resistance make it suitable for extreme environments, such as offshore platforms and mining sites 813.
  • IP20 protection and vibration/shock resistance (IEC 60068-2-6/27) ensure reliability in rugged industrial settings.

 

Efficient Integration:

 

  • TU810/TU830 terminal units provide power distribution and signal termination for field devices 9.
  • Symphony Plus/800xA compatibility allows seamless integration with ABB’s control platforms, enabling centralized monitoring and control 24.

Application Areas

  1. Power Generation:
    • Monitoring steam turbine temperatures and boiler combustion efficiency. Cold junction compensation ensures accurate readings in high-temperature environments 8.
  2. Oil & Gas:
    • Optimizing pipeline flow rates and compressor station temperatures. Supports predictive maintenance of smart thermocouples via HART communication 6.
  3. Chemical & Petrochemical:
    • Controlling reactor processes and distillation units. Corrosion-resistant design ensures stability in chemical plants 8.
  4. Water & Wastewater:
    • Regulating pump stations and water treatment systems. Thermocouple inputs interface with temperature sensors for process optimization 6.
  5. Manufacturing:
    • Managing robotics and conveyor systems in automotive production. High-speed sampling supports synchronization with PLCs and SCADA systems 7.

Related Products

  1. TU810/TU830 Terminal Units: Required for physical installation and signal termination, providing power distribution 9.
  2. PM864AK02 Processor Module: Complementary controller for Symphony Plus, enabling real-time data processing.
  3. AI835A High-Precision Module: Supports additional TC types (D, L, U) and features 16-bit resolution for enhanced accuracy 1327.
  4. Symphony Plus DCS Platform: ABB’s integrated control system fully compatible with the AI835.
  5. Freelance Engineering Software: Configures the module’s parameters and diagnostics for optimized performance.

Installation and Maintenance

Installation:

 

  • Mounting: Secure on a 35 mm DIN rail using M4 screws, with TU810 or TU830 terminal units for power and signal connections 9.
  • Wiring: Connect 24 VDC power and route shielded cables for thermocouple inputs. Use TB801A terminal blocks for reliable signal termination.
  • Configuration: Use ABB Freelance Engineering to assign I/O addresses, select TC types, and enable cold junction compensation via Channel 8 9.

 

Maintenance:

 

  • Routine Checks: Inspect terminal connections quarterly for tightness and corrosion. Clean dust from vents using compressed air.
  • Firmware Updates: Regularly update firmware via Freelance Engineering to access new features and security patches.
  • Redundancy Testing: For mission-critical systems, pair with redundant processor modules (e.g., PM864AK02) and perform annual failover tests.
  • Spare Parts Management: Maintain inventory of critical modules (e.g., AI835) to reduce downtime. ABB offers expedited delivery for urgent replacements 8.

Product Assurance

The ABB AI835 is backed by a 1-year warranty covering defects in materials and workmanship. ABB provides global technical support, including access to certified engineers and comprehensive documentation (e.g., datasheets, installation manuals) 825. For mission-critical applications, ABB offers extended warranties (up to 5 years) and proactive maintenance plans, including annual system health checks to ensure compliance with safety standards 8.

 

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