ABB AI825 (3BSE036456R1) – S800 analog input module for 4–20 mA/HART field transmitters

The ABB AI825 is part of the S800 I/O family and is typically used to bring eight channels of 4–20 mA process signals—often with HART passthrough—into AC 800M–based systems or S800 I/O islands. From my experience, it’s the go-to when you need clean current inputs from loop-powered or externally powered transmitters, with dependable diagnostics and straightforward DIN-rail deployment via S800 termination units.

Company’s Order Placement Process and Guarantees

• Warranty: 365 days
• Delivery: 1 week if in stock; no more than one month at the latest
• Payment: 50% advance payment; full payment before delivery
• Express options: FedEx, UPS, DHL

Key Features

• 8-channel 4–20 mA analog input – Designed for process transmitters handling flow, pressure, level, and temperature (via converter).
• HART passthrough support – In many cases, HART data can be passed to asset management tools for configuration and diagnostics.
• S800 ModuleBus backplane interface – You might notice that there’s no external comm port; it plugs into the S800 termination unit and the backplane does the rest.
• Diagnostics and channel status – Front LEDs and internal fault reporting typically simplify troubleshooting during commissioning.
• Compact DIN-rail mounting – Fits standard S800 termination units (TU8xx series), helping keep cabinets dense and tidy.
• Flexible wiring concepts – Works with loop-powered or externally powered transmitters depending on selected TU and field wiring.

Technical Specifications

Application Fields

The AI825 seems to be a solid choice for process industries where current loops dominate. Typical scenarios include:

• Oil & gas – pressure and flow transmitters feeding AC 800M control strategies
• Chemical & petrochemical – continuous level, density, and analyzer signals with HART diagnostics
• Water & wastewater – differential pressure and magflow loops in distributed cabinets
• Power & utilities – condenser vacuum, feedwater, and auxiliary process transmitters
• Pulp & paper & food – hygienic transmitters where quick swap and simple loop checks matter

“We swapped older AI cards for AI825s on a clarifier line; HART passthrough made calibrations quicker and the wiring on the TU stayed neat. Commissioning was smoother than expected.” — Maintenance supervisor, municipal WTP

Advantages & Value

• Reliability – In most cases, S800 I/O runs for years without drift issues, which reduces unscheduled work.
• Compatibility – Works within the ABB S800 ecosystem, tying neatly to AC 800M and common S800 linking devices.
• Cabinet efficiency – The compact module and TU design save rail space and simplify loop segregation.
• Lifecycle support – ABB documentation and parts availability are generally strong for the S800 line.
• Cost control – HART passthrough can cut site trips for transmitter tweaks, saving labor over time.

Installation & Maintenance

• Cabinet & environment – Install in a ventilated enclosure meeting at least IP20 internal standards; avoid condensation; follow 0…55 °C guidelines.
• DIN-rail mounting – Seat the AI825 firmly on a compatible TU (e.g., TU830V1/TU835V1). Verify ModuleBus connectors are fully engaged.
• Wiring – Use shielded twisted pair for analog loops; land shields per site EMC practice. For loop-powered devices, provide 24 VDC feed via the TU as per ABB wiring diagrams.
• Grounding & segregation – Separate analog from high-noise conductors; keep analog returns clean to minimize measurement noise.
• Safety – De-energize the loop before landing wires. Confirm channel polarity and terminal references to avoid input saturation.
• Routine checks – Periodic loop verification and transmitter calibration (typically annually). Keep firmware for the controller/I/O family current when recommended by ABB.
• Spare strategy – From my experience, keeping at least one spare AI825 per panel row reduces recovery time during outages.

Quality & Certifications

• CE compliant; typically UL/cUL recognized for industrial control equipment
• RoHS-compliant build for most modern revisions
• Manufactured under ISO 9001 quality systems
• Standard manufacturer warranty terms apply; unit-specific warranty here is 365 days

Related/Supporting Components

• Termination Units (TUs) – TU830V1 or TU835V1 are commonly paired when powering 2‑wire transmitters; TU810V1/TU812V1 are also used depending on wiring method.
• System integration – AC 800M controllers with S800 I/O; S800 linking devices for fieldbus integration where required.
• Field accessories – HART modem/interface for asset management, shielded cable, and proper DIN-rail power distribution for 24 VDC loops.

Note: Specifications above reflect typical S800 I/O characteristics for AI825 (3BSE036456R1). If you’re matching an existing installation, share the TU model and wiring concept—small details here usually ensure a first‑time‑right swap.