Description

Product Overview

The ABB DI93A HESG440355R3 is a 32-channel digital input module engineered for ABB’s S800 I/O system, delivering ultra-high-density signal acquisition for large-scale industrial automation. As a core component of the S800 family, this module consolidates 32 current-sinking (NPN) inputs into two galvanically isolated groups of 16 channels each, optimizing space in control cabinets while enabling fail-safe monitoring of critical processes. The DI93A supports 24 VDC input signals with 500 VAC dielectric isolation and software-configurable filtering (2–32 ms), ensuring reliable operation in noisy environments like automotive plants, chemical facilities, or offshore platforms.

Designed for seamless integration with ABB’s AC 800M controllers and Freelance DCS, the DI93A features a hot-swappable design compatible with termination units (e.g., TU840) for maintenance without system downtime. The revision HESG440355R3 incorporates enhanced surge protection and diagnostic capabilities, including real-time channel status indicators and voltage supervision for each input group, making it ideal for mission-critical applications requiring high availability.

Technical Specifications

Parameter Name	Parameter Value
Product Model	DI93A HESG440355R3
Manufacturer	ABB
Product Type	Digital Input Module for S800 I/O System
Input Channels	32 (2 isolated groups of 16 channels)
Input Type	Current-sinking (NPN), 24 VDC
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 between channels 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 (up to +70°C short-term)
Certifications	CE, UL, CSA, ATEX Zone 2, IECEx, marine approvals (ABS, DNV)
Communication	PROFIBUS DP via S800 I/O bus module

Main Features and Advantages

High-Density Signal Acquisition: The 32-channel design reduces hardware costs by 50% compared to deploying multiple 16-channel modules, ideal for systems with extensive sensor networks (e.g., automotive assembly lines with hundreds of proximity sensors). Dual isolated groups enable segregating safety-critical and non-critical signals, minimizing cross-interference.

Enhanced Diagnostic Capabilities: Real-time monitoring of channel status, short-circuit detection, and group-level voltage supervision facilitate proactive maintenance. The HESG440355R3 revision includes upgraded transient voltage suppression (TVS) diodes, protecting against surges from inductive loads and extending module lifespan in harsh environments.

Rugged Industrial Design: Withstands electromagnetic interference (EMI) and voltage spikes, certified for use in hazardous areas (ATEX/IECEx) and marine applications. The hot-swappable design allows replacement during operation, critical for 24/7 processes in power plants or wastewater treatment facilities.

Modular System Integration: Compatible with ABB’s TU840 terminal units and BM820 bus modules, supporting scalable configurations from small panels to multi-rack systems. Seamlessly integrates with ABB’s Control Builder M software for intuitive configuration of filtering, fail-safe states, and diagnostic parameters.

Application Areas

Manufacturing Automation:

Automotive Production: Monitors robotic arm sensors, safety interlocks, and conveyor belt positions in body-in-white lines, integrating with ABB’s RobotStudio for synchronized motion control.
Packaging & Food Processing: Reads product presence sensors, capping machine statuses, and conveyor speed switches in hygienic environments (compliant with IP65 standards).

Process Industries:

Chemical & Oil Refineries: Tracks valve positions, pressure switches, and emergency stop buttons in distillation columns and pipeline networks, supporting SIL2 safety systems.
Pharmaceutical Plants: Monitors agitator run signals and sterile chamber door statuses, ensuring GMP compliance for batch processes.

Energy & Infrastructure:

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

Installation & Maintenance

Installation:

Mount the DI93A on a DIN rail with ≥50 mm clearance for heat dissipation.
Connect field wires to the TU840 terminal block following NPN (current-sinking) wiring diagrams.
Link to the S800 I/O bus and configure via Control Builder M, setting filtering time based on environment (e.g., 8 ms for motor-driven applications).

Maintenance:

Regularly inspect LED indicators for channel faults and use ABB’s System 800xA for remote condition monitoring.
Clean the module with compressed air (≤0.6 bar) quarterly in dusty environments to prevent heat buildup.
Replace faulty modules using hot-swap functionality, ensuring TU840 is disconnected from field wiring to avoid transients.

Product Guarantee

ABB warrants the DI93A HESG440355R3 against defects for 1 year, covering materials and workmanship. The module meets global safety standards (CE, UL, ATEX) and is supported by ABB’s 24/7 technical service network. Customers gain access to firmware updates via ABB’s Service Portal and can opt for premium support contracts, including priority spare parts and on-site commissioning services, ensuring optimal performance in critical applications.

HS:7326909000

Contact info

WhatsApp: +86 18030182217
Email: sandydcsplc@gmail.com
Phone: +86 18030182217
Wechat: +86 18030182217
Website: www.xiongbaparts.com

ABB DI93A HESG440355R3 Digital Input Module for S800 I/O System(XIONGBA)