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ABB AI895 8-Channel Analog Input Module
1. Product Overview
The ABB AI895 is an industrial-grade 8-channel analog input module tailored for the ABB S800 I/O system. Engineered to offer reliable and accurate current signal acquisition in industrial automation setups, it stands out with its intrinsic safety (IS) features. This allows for direct connection to field devices in hazardous areas, eliminating the need for external safety barriers. It supports 4 - 20 mA single-ended non-polar current inputs and incorporates HART communication, enabling seamless transmission of process variables and digital diagnostic data, streamlining on-site instrument management.
2. Technical Specifications
2.1 Input Performance & Compatibility
- Channel Count: Features 8 independent channels grouped as a single isolation unit, isolated from ground to prevent cross-channel interference.
- Supported Signal Types: Exclusive support for 4 - 20 mA single-ended non-polar current inputs. This compatibility aligns well with a vast array of standard industrial sensors, such as pressure transmitters, flow meters, and level sensors that output these current signals.
- Resolution: Boasts a 12-bit resolution, ensuring a reasonable level of precision suitable for most industrial applications. This enables the module to detect minute changes in input signals, translating to more accurate data representation for control and monitoring systems.
- Update Cycle Time: Has a rapid 5 ms update cycle per channel, allowing for quick sampling of input signals. This is especially beneficial in applications where real-time data is crucial, like fast-paced process control scenarios.
2.2 Safety Features
- Intrinsic Safety: Equipped with intrinsic safety protection on each channel. Compliant with ATEX/IECEx Zone 2 interface to Zone 0 and CFMUS C1, Div 2/Zone 2 interface to C1, C2, C3 Div 1/Zone 0 standards, it can be used directly in hazardous areas without additional external safety barriers. This ensures that electrical energy within the module is restricted to prevent 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, powering 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, mainly used for powering external two-wire transmitters.
- Transmitter Power: Each channel can power or monitor an Ex-certified two-wire process transmitter. It provides at least 15 V at a 20 mA loop current for Ex-certified process transmitters. In overload conditions, the current is limited to 23 mA to safeguard both the transmitter and the module.
- Input Voltage Drop: For current input, the typical input voltage drop is 3 V (including the effect of the PTC resistor), an important factor 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, even in applications where multiple I/O modules need to be stacked.
- Mounting: Designed for standard DIN rail mounting, following common industry standards for easy integration into industrial control panels.
- Operating Temperature: -25 °C to +60 °C, suitable for a wide range of industrial environments, including both indoor control rooms and some more challenging outdoor or high-temperature industrial settings. However, additional cooling or heating measures may be required in extreme conditions.
- Humidity: Can operate in 5% - 95% non-condensing humidity, ensuring reliable performance in various environmental conditions.
3. Application Fields
- Oil & Gas Industry: In oil refineries and gas processing plants, the AI895 is used to collect 4 - 20 mA signals from pressure sensors in pipelines, flow meters in transfer stations, and level sensors in storage tanks. Its intrinsic safety feature is essential in these environments where flammable substances are present.
- Chemical Plants: Ideal 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 wiring and installation in complex chemical process setups.
- Mining Operations: In mines, it can 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 significant advantage in the potentially explosive atmosphere of mining areas.
- Pharmaceutical Industry: Used to monitor critical process parameters in pharmaceutical manufacturing, such as temperature and pressure during drug synthesis. The HART communication feature enables efficient monitoring and control of field devices, ensuring product quality and compliance with industry regulations.
4. Installation & Maintenance
4.1 Installation
- Mounting: Install the AI895 module on a standard DIN rail. Ensure the DIN rail is properly grounded according to electrical safety standards. Use appropriate mounting clips or screws to firmly secure the module in place.
- Wiring: Connect the 4 - 20 mA signals from field sensors to the designated input terminals on the module. For two-wire transmitters, ensure correct wiring of power connections from the module to the transmitters. Use shielded cables to minimize electromagnetic interference, especially in areas with high electrical noise.
- Configuration: Configure the module within the ABB S800 I/O system software. Set the appropriate input signal range (4 - 20 mA) for each channel according to the connected sensors. Enable HART communication settings if required for two-way communication with field devices.
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 (e.g., fault, operation, warning, HART communication LEDs) to ensure all channels are functioning properly.
- Cleaning: Use a dry, soft brush to clean dust and debris from the module, particularly from ventilation slots and terminal areas. Avoid using liquid cleaners or solvents that could damage electronic components.
- Calibration: Calibrate the module periodically (e.g., annually) using a calibrated current source. Inject known 4 - 20 mA signals into the input channels and compare the readings on the control system with expected values. Adjust 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 replacement. Ensure the new module has the same part number and is properly configured in the system.
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