ABB DI840 (3BSE020836R1) S800 I/O High-Density Digital Input Module(XIONGBA)

ABB DI840 (3BSE020836R1) S800 I/O High-Density Digital Input Module(XIONGBA)

Brand Model: ABB DI840 (Spare Part No. 3BSE020836R1)
Product Name: S800 I/O High-Density Digital Input Module
Warranty: 1 year
Size: 102 mm × 119 mm × 45 mm (depth × height × width)
Weight: 0.18 kg
Origin: Sweden (manufactured under ABB’s global quality standards)
Inventory Status: Stocked in Xiamen warehouse
Delivery Lead Time: 2–5 working days after payment

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Description

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Product Overview

The ABB DI840 (3BSE020836R1) is a 32-channel digital input module designed for ABB’s S800 I/O system, offering the highest channel density in the DI series. Unlike the 16-channel DI814, the DI840 consolidates 32 current-sinking (NPN) inputs into two isolated groups of 16 channels each, making it ideal for large-scale systems requiring high-signal density. It supports 24 VDC input signals with galvanic isolation (50 V rated, 500 VAC dielectric strength) and integrates voltage supervision for each group, enabling fail-safe monitoring in critical applications like safety interlocks or process automation. The module’s software-configurable input filtering (2–32 ms) and EMC protection ensure reliable operation in noisy environments, such as automotive plants or steel mills.


Featuring a hot-swappable design compatible with termination units like TU840, the DI840 allows maintenance without system shutdown. It interfaces with ABB’s AC 800M controller and Freelance DCS via PROFIBUS DP, supporting real-time diagnostics through channel-specific LED indicators and integrated fault reporting. The spare part number 3BSE020836R1 denotes Revision 1, which includes enhanced surge protection compared to earlier versions.

Technical Specifications

Parameter Name Parameter Value
Product Model DI840
Spare Part Number 3BSE020836R1
Manufacturer ABB
Channel Configuration 32 channels (2 isolated groups of 16 channels)
Input Type Current-sinking (NPN)
Input Voltage Range 18–30 VDC (logic “1”), ≤5 VDC (logic “0”)
Input Current 4 mA (per channel at 24 VDC)
Response Time ≤1 ms (filter disabled)
Galvanic Isolation 50 V rated, 500 VAC dielectric test (between channels/groups and backplane)
Filtering Software-selectable (2, 4, 8, 16, 32 ms)
Power Supply 24 VDC (via S800 I/O backplane)
Power Consumption ≤2.5 W
Operating Temperature -20°C to +60°C (with derating up to +70°C for short periods)
Storage Temperature -40°C to +85°C
Certifications CE, UL, CSA, ATEX Zone 2 (gas), IECEx, marine approvals (ABS, DNV, GL)
Communication Protocol PROFIBUS DP (via S800 I/O bus module)

Key Features & Advantages

Ultra-High Channel Density: The 32-channel design reduces cabinet space by 50% compared to deploying two 16-channel modules, lowering hardware costs for large systems (e.g., automotive assembly lines with hundreds of sensors).


Dual Isolation Groups: Each group of 16 channels is electrically isolated, preventing cross-interference and allowing partial system maintenance without disrupting critical signals (e.g., separating safety-critical inputs from non-safety inputs).


Enhanced Diagnostics: Real-time monitoring of each channel’s status, short-circuit detection, and group-level voltage supervision. Diagnostic data is accessible via the controller, enabling predictive maintenance (e.g., identifying failing sensors before system errors occur).


Surge Protection (R1 Revision): The 3BSE020836R1 incorporates upgraded transient voltage suppression (TVS) diodes, protecting against voltage spikes from inductive loads (e.g., solenoid valves) and extending module lifespan in harsh industrial environments.


Modular Compatibility: Works with ABB’s S800 I/O Termination Units (TU840 for screw terminals, TU840V1 for spring terminals) and bus modules (BM820), supporting scalable configurations from small panels to multi-rack systems.

Application Scenarios

Manufacturing & Automotive:


  • Body-in-White Production: Monitors 32+ proximity sensors on robotic welders, door position switches, and safety light curtains, integrating with ABB’s RobotStudio for synchronized motion control.
  • Packaging Lines: Reads conveyor belt speed switches, product presence sensors, and capping machine statuses in food & beverage facilities (compliant with IP65-rated environments).


Process Automation:


  • Chemical Plants: Tracks valve positions in distillation columns, agitator run signals, and emergency stop buttons, supporting SIL2 safety systems when paired with ABB’s Safety Builder M.
  • Oil Refineries: Monitors pressure switches in pipeline networks, fire/smoke detectors, and flare stack statuses, interfacing with ABB’s OMS800 for emergency shutdown protocols.


Energy & Infrastructure:


  • Substation Automation: Reads circuit breaker positions, relay statuses, and transformer tap changer signals, compatible with ABB’s REL500 series protective relays.
  • Metro Rail Systems: Monitors door closure sensors, platform screen door statuses, and track switch positions, meeting EN 50155 (railway environmental standards).

Related Products & Compatibility

  1. ABB TU840 Terminal Unit: 32-channel removable terminal block for DI840, supports quick wiring and replacement (Part No. 3BSE008429R1).
  2. ABB BM820 Bus Module: Connects S800 I/O racks to the AC 800M controller, supports up to 16 modules per rack (Part No. 3BSE018159R1).
  3. ABB DI841: 32-channel digital input module for 48 VDC applications (spare part No. 3BSE020837R1).
  4. ABB AC 800M Controller PM866: Redundant CPU for large S800 I/O systems, supports up to 1024 digital inputs (Part No. 3BSE018270R1).
  5. ABB Control Builder M Software: Configures DI840 filtering, fail-safe states, and diagnostics (Version 3.2 or higher).

Installation & Maintenance

Installation Steps:


  1. Mount the module on a DIN rail in a control cabinet with ≥50 mm air clearance for cooling.
  2. Connect field wires to the TU840 terminal block, following NPN (current-sinking) wiring diagrams (e.g., common cathode configuration).
  3. Link the module to the S800 I/O bus via a bus cable, and configure inputs using Control Builder M (set filtering time based on signal noise level, e.g., 8 ms for machinery with motor interference).


Maintenance Tips:


  • Use ABB’s System 800xA Condition Monitoring to track module health metrics (e.g., channel error rates, power consumption trends).
  • In dusty environments, clean the module with compressed air (≤0.6 bar) every 季度 to prevent dust accumulation.
  • For hot-swapping, ensure the TU840 is disconnected from field wiring before replacing the DI840 to avoid transient currents.

Product Warranty & Support

The DI840 (3BSE020836R1) is covered by ABB’s standard 1-year warranty against manufacturing defects. It complies with global safety and environmental standards (ATEX, IECEx, marine certifications), making it suitable for hazardous areas and offshore applications. ABB’s Service Portal offers firmware updates (latest revision R1.2 as of 2025) and technical bulletins, while regional service centers provide 24/7 support for urgent issues. For large projects, ABB offers Commissioning Services to ensure optimal configuration and integration with existing systems.


With its high-channel density, robust isolation, and advanced diagnostics, the DI840 (3BSE020836R1) is designed for industrial applications requiring reliable, large-scale digital signal acquisition in demanding environments.
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