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ABB 3BUS208802-002 Digital Input Module  

1. Key Parameters

• Product Model: 3BUS208802-002
• Order Code: 3BUS208802-002
• Product Series: ABB AC500 PLC Digital Input Modules (16-Channel, 24V DC, High-Speed)
• Core Function: Acquires discrete digital signals from field sensors; provides electrical isolation between field circuits and PLC backplane; filters electrical noise to ensure signal stability; supports high-speed signal capture for time-sensitive applications
• Electrical Specifications:

  Parameter	Details	Performance Metrics
  Number of Channels	16 independent digital input channels (configurable as groups)	Covers multi-sensor signal acquisition needs
  Input Signal Type	24V DC (sinking/sourcing configurable via DIP switch); Dry/wet contact compatible	Works with most industrial digital sensors
  Input Voltage Range	- Logic "1" (ON): 15V DC ~ 30V DC - Logic "0" (OFF): 0V DC ~ 5V DC	Complies with IEC 61131-2 industrial standards
  Input Current	4mA ~ 8mA (at 24V DC, logic "1")	Low power consumption to avoid sensor overload
  Response Time	- Standard mode: ≤1ms (per channel) - High-speed mode: ≤100μs (per channel, configurable for 8 channels)	Captures fast transient signals (e.g., machine position triggers)
  Isolation Level	2kVrms (between input channels; between inputs and PLC backplane; 1min dielectric test)	Prevents ground loops and noise coupling
  Noise Filtering	Configurable digital filter (0.1ms ~ 100ms) via ABB Automation Builder software	Reduces 50/60Hz grid noise and EMI

• Mechanical Specifications:
  • Form Factor: PLC backplane-mounted module (compatible with AC500 I/O racks)
  • Dimensions (W×H×D): 35mm × 100mm × 120mm (compact design for dense I/O racks)
  • Mounting: Snap-on installation to AC500 I/O backplane; no tools required for insertion/removal
  • Weight: Approximately 130g
  • Connectors: 2× 10-pin spring-cage terminals (for sensor wiring); Gold-plated contacts for low contact resistance
  • LED Indicators (front panel):
    • Power (PWR): Green (module powered on via backplane)
    • Channel Status (CH1~CH16): Green (signal "ON"/logic "1"); Off (signal "OFF"/logic "0")
    • Mode (MODE): Amber (high-speed mode active); Off (standard mode)
• Environmental Ratings:
  • Operating Temperature Range: -25℃ ~ +60℃ (-13℉ ~ 140℉)
  • Storage Temperature Range: -40℃ ~ +85℃ (-40℉ ~ 185℉)
  • Humidity Tolerance: ≤95% RH (non-condensing, 40℃; suitable for damp industrial areas)
  • Vibration Resistance: 10~500Hz, 1.5g acceleration (IEC 60068-2-6; no signal loss or connector 松动)
  • Shock Resistance: 20g acceleration (11ms duration, IEC 60068-2-27; maintains backplane communication)
  • Protection Rating: IP20 (front panel; protects against finger contact and small debris)
• Compliance Standards: IEC 61131-2 (industrial control equipment), EN 61000-6-2 (EMC immunity), UL 508 (industrial safety), CE, RoHS, ATEX (optional Ex approval for hazardous areas)

2. Key Features

• ABB AC500 PLC Exclusivity: Custom-engineered for AC500 series PLCs—seamlessly integrates with the AC500 backplane for plug-and-play operation; automatic module detection via ABB Automation Builder software eliminates manual configuration, reducing installation time by 30%.
• 16-Channel High-Density Design: 16 independent input channels in a 35mm-wide module maximize I/O rack space efficiency—ideal for control cabinets with multiple sensors (e.g., 16 limit switches in a conveyor system), reducing the number of required modules by 50% compared to 8-channel alternatives.
• Dual Operation Modes: Supports standard mode (≤1ms response) for general-purpose sensing and high-speed mode (≤100μs response) for time-sensitive applications (e.g., machine vision triggers, high-speed counting)—adapts to diverse automation needs without hardware upgrades.
• 2kVrms Electrical Isolation: Reinforced isolation between input channels and the PLC backplane suppresses electrical noise from nearby motors, VFDs, or welding equipment—ensures stable signal acquisition in electrically harsh environments (e.g., steel mills, automotive welding stations).
• Configurable Filtering: Digital filters (0.1ms~100ms) adjustable via software enable tailored noise reduction—e.g., 100ms filters for noisy industrial grids, 0.1ms filters for fast-moving equipment (e.g., robotic arms), preventing false triggers.
• Spring-Cage Terminals: Tool-free spring-cage terminals simplify sensor wiring and reduce installation time by 40% compared to screw-clamp terminals; gold-plated contacts ensure long-term connectivity (≥10,000 mating cycles) in vibration-prone environments.
• Wide Temperature Range: -25℃~+60℃ operating range adapts to extreme conditions (e.g., cold storage facilities for food processing, high-temperature foundries)—ensures reliable signal acquisition in 99% of industrial settings.

3. Application Fields

• AC500 PLC-Based Factory Automation: Primary application—digital signal acquisition for manufacturing:
  • Automotive Assembly Lines: Acquires signals from 16 proximity sensors (detecting bolt presence, part alignment) in AC500 PLCs; high-speed mode (≤100μs) captures fast-moving part triggers, ensuring synchronized robotic welding and reducing defect rates by 15%.
  • Electronics Production: Collects digital signals from SMT machine photoelectric sensors (PCB presence, component placement confirmation); 2kVrms isolation resists noise from soldering equipment, preventing false shutdowns of SMT lines.
• Process Control Auxiliaries: Monitors equipment status in process industries:
  • Food & Beverage Processing: Connects to 16 limit switches (tank level, door safety) in AC500-eCo PLCs; configurable filtering (50ms) eliminates noise from washing equipment, ensuring reliable control of filling and capping machines—complies with food industry hygiene standards (easy-to-clean design).
  • Chemical Plant Auxiliaries: Monitors valve position sensors (open/closed) and pump status switches; 2kVrms isolation prevents ground loops from chemical dosing pumps, ensuring accurate tracking of process steps (e.g., reactor feeding, mixing).
• Infrastructure & Logistics Automation: Supports reliable sensing in critical infrastructure:
  • Warehouse Conveyors: Acquires signals from 16 photoelectric sensors (package detection, conveyor jam alerts) in AC500 PLCs; spring-cage terminals simplify wiring during conveyor expansion, reducing downtime for warehouse upgrades.
  • Water Treatment Plants: Monitors float switch signals (tank overflow, low-level alerts) and pump start/stop status; wide temperature range (-25℃~+60℃) withstands outdoor pump station environments, ensuring uninterrupted water treatment.

4. Precautions

• PLC Compatibility: Use exclusively with ABB AC500 series PLCs (AC500-CPU310/320/410/420) and AC500-eCo CPUs (PM564/PM573). Never install in non-ABB PLCs or incompatible ABB systems (e.g., IRC5 robots)—backplane pinout and communication protocol mismatches will damage the module or PLC.
• Input Voltage Limits: Do not exceed 30V DC input voltage or operate below 15V DC for logic "1"—overvoltage (>30V) burns out input circuits, while undervoltage (<15V) causes false "OFF" signals. Verify sensor power supplies (24V DC ±10%) with a multimeter before wiring.
• Electrical Safety:
  • Power Disconnection: Disconnect the AC500 PLC from 24V DC backplane power before installing/removing the module—exposed terminals carry live voltage (up to 24V DC), posing shock risks. Use insulated tools for wiring.
  • Grounding Requirements: Connect sensor cable shields to the module’s dedicated ground terminal (or PLC rack ground); use single-point grounding (shield grounded only at the module end) to maintain 2kVrms isolation—poor grounding increases noise susceptibility, leading to false triggers.
• Wiring & Channel Configuration:
  • Sinking/Sourcing Setup: Set the DIP switch to match the sensor type (sinking/sourcing) before power-on—incorrect settings (e.g., sinking mode for a sourcing sensor) result in no signal detection. Refer to the module’s wiring diagram for DIP switch positions.
  • Cable Specifications: Use shielded twisted-pair cables (24AWG~20AWG) for sensor wiring; keep cables at least 15cm away from power cables (e.g., VFD motor cables) to avoid EMI—unshielded or improperly routed cables cause signal drift (e.g., intermittent "ON"/"OFF" states).
• Environmental Protection:
  • Temperature & Humidity: Avoid operating above +60℃ or in condensing humidity (>95% RH with condensation)—high temperatures reduce input circuit lifespan, while condensation causes terminal corrosion, leading to increased contact resistance.
  • Dust & Vibration: Install the AC500 PLC in a dust-tight enclosure (IP54 or higher) in dusty environments (e.g., cement plants, grain silos); use vibration-damping mounts for PLC racks in high-vibration equipment (e.g., compressors)—excessive vibration loosens spring-cage terminals, causing signal loss.
• Maintenance & Testing:
  • Quarterly Visual Inspection: Check LED indicators to confirm normal operation (PWR green, CH1~CH16 green/off per sensor status); amber LEDs for faulty channels indicate wiring issues or sensor failure—resolve immediately to avoid process disruption.
  • Signal Verification: Annually test input channels with a 24V DC test signal (simulating sensor "ON"/"OFF")—channels with delayed response (>1ms in standard mode) indicate filter degradation or contact wear, requiring module cleaning or replacement.
  • Software Backup: Save module configuration (filter settings, high-speed mode channels) via ABB Automation Builder—factory reset or PLC firmware updates may erase settings, requiring reconfiguration

The structure and details of the product：

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