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ABB AI890 8-Channel Analog Input Module
1. Product Overview
The ABB AI890 is an industrial-grade 8-channel analog input module designed for ABB S800 I/O system. It is specifically engineered to collect, condition, and transfer analog signals from field sensors in hazardous areas, with high precision and intrinsic safety features. Its compact design and single-ended unipolar input compatibility make it suitable for industries such as oil & gas, chemical plants, and mining where safety and reliable signal acquisition are crucial.
2. Technical Specifications
2.1 Input Performance & Compatibility
- Channel Count: 8 independent channels grouped as one isolation unit (isolated from ground), ensuring no interference between channels.
- Supported Signal Types: Only 0 - 20 mA DC or 4 - 20 mA DC single-ended unipolar inputs are supported. This simplicity in signal types allows for straightforward connection with a wide range of standard industrial sensors, like pressure transmitters, flow meters, and level sensors that output these current signals.
- Resolution: 12-bit resolution, which provides a reasonable level of precision for most industrial applications. This means it can distinguish between small changes in the input signal, translating to more accurate data representation for control and monitoring systems.
- Update Cycle Time: 5 ms per channel, enabling relatively fast sampling of the input signals. This is beneficial for applications where real-time data is crucial, such as in fast - changing process control scenarios.
2.2 Safety Features
- Intrinsic Safety: Equipped with intrinsic safety protection on each channel. This allows the module to be used directly in hazardous areas (classified as per relevant explosion-proof standards) without the need for additional external safety barriers. It ensures that any electrical energy within the module is limited in such a way that it cannot cause an ignition in the presence of flammable gases or dust.
2.3 Electrical Characteristics
- Module bus +5 V: Typical consumption is 70 mA, with a maximum of 150 mA. This power is used for the internal logic and signal processing within the module.
- +24 V external: Typical consumption is 220 mA, with a maximum of less than 300 mA. The +24 V is mainly used for powering external two - wire transmitters.
- Transmitter Power: Each channel can power or monitor an Ex-certified two - wire process transmitter. The transmitter supply for each channel can provide at least 15 V at a 20 mA loop current to power the Ex-certified process transmitters. In overload conditions, the current is limited to 23 mA to protect both the transmitter and the module.
- Input Voltage Drop: For the current input, the typical input voltage drop is 3 V (including the effect of the PTC resistor). This voltage drop is an important consideration when calculating the overall power budget for the sensor - transmitter - module system.
2.4 Mechanical & Environmental
- Dimensions: Width: 45 mm, Depth: 102 mm, Height: 119 mm. Its compact size allows for easy installation in control cabinets with limited space, especially in applications where multiple I/O modules need to be stacked together.
- Mounting: Designed to be mounted in a standard DIN rail setup, following the common industry standards for easy integration into industrial control panels.
- Operating Temperature: 0 to +55 °C. This temperature range is suitable for most indoor industrial environments, including those in control rooms and some protected areas within industrial plants. However, it may require additional cooling or heating measures in extreme temperature conditions.
3. Application Fields
- Oil & Gas Industry: In oil refineries and gas processing plants, the AI890 can be used to collect 4 - 20 mA signals from pressure sensors in pipelines, flow meters in transfer stations, and level sensors in storage tanks. The intrinsic safety feature is crucial in these environments where flammable substances are present.
- Chemical Plants: For monitoring various process variables such as temperature (through temperature transmitters converted to 4 - 20 mA signals), pressure in reaction vessels, and flow rates of chemical feedstocks. The module's ability to power two - wire transmitters simplifies the wiring and installation process in complex chemical process setups.
- Mining Operations: In mines, it can be used to receive signals from sensors measuring gas concentration (e.g., methane sensors converted to current signals), pressure in ventilation systems, and level of slurry in processing tanks. The intrinsic safety of the module is a key advantage in the potentially explosive atmosphere of mining areas.
4. Installation & Maintenance
4.1 Installation
- Mounting: Install the AI890 module on a standard DIN rail. Ensure that the DIN rail is properly grounded as per electrical safety standards. Use appropriate mounting clips or screws to secure the module firmly in place.
- Wiring: Connect the 0 - 20 mA or 4 - 20 mA signals from the field sensors to the designated input terminals on the module. For two - wire transmitters, ensure that the power connections from the module to the transmitters are correctly wired. Use shielded cables to minimize electromagnetic interference, especially in areas with high electrical noise.
- Configuration: Although the AI890 has a relatively simple configuration for the supported signal types, it may need to be configured within the ABB S800 I/O system software. Set the appropriate input signal range (0 - 20 mA or 4 - 20 mA) for each channel as per the connected sensors.
4.2 Maintenance
- Regular Inspection: Periodically (e.g., monthly) inspect the module for any signs of physical damage, such as loose connections, discolored terminals, or a damaged housing. Check the status indicators on the module (if available) to ensure that all channels are functioning properly.
- Cleaning: Use a dry, soft brush to clean the dust and debris from the module, especially from the ventilation slots and terminal areas. Avoid using liquid cleaners or solvents that could damage the electronic components.
- Calibration: While the AI890 is designed to be relatively stable, it may be necessary to calibrate the module periodically (e.g., annually). Use a calibrated current source to inject known 0 - 20 mA or 4 - 20 mA signals into the input channels and compare the readings on the control system with the expected values. Adjust the calibration settings if necessary.
- Replacement: If a channel fails or shows abnormal behavior, first check the wiring and connections to the sensor. If the problem persists, the module may need to be replaced. When replacing the module, ensure that the new module has the same part number and is properly configured in the system.
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