ABB AI810 (3BSE008516R1) Analog Input Module for S800 I/O – dependable current input for process control

The ABB AI810 is an analog input module from the S800 I/O family, designed for stable and precise current measurements in distributed control systems. From my experience, it’s a go‑to choice when you need clean 0/4–20 mA signals integrated into ABB AC 800M–based architectures or as a drop‑in replacement in existing S800 I/O racks. One thing I appreciate is how predictable it is in real plants—instrument loops stay quiet, diagnostics are straightforward, and commissioning typically goes faster than expected.

Company’s Order Placement Process and Guarantees

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

Key Features

• Multi‑channel 0/4–20 mA inputs – Suited for standard process transmitters (pressure, level, flow, temperature via converters).
• S800 I/O ecosystem compatibility – Works within ABB’s modular S800 platform for AC 800M and 800xA systems, keeping engineering consistent.
• Stable signal conditioning – Designed for low noise and good repeatability; you might notice fewer erratic readings in long cable runs.
• Diagnostic feedback – Channel and module status help speed up troubleshooting in most cases.
• HART pass‑through (commonly used) – Many installations use AI810 to pass HART information to asset management tools, reducing on‑site trips.
• DIN‑rail installation via termination units – Quick swap on TU8xx series base units, which helps reduce downtime.

Technical Specifications

Brand / Model	ABB AI810 – 3BSE008516R1 (S800 I/O Analog Input Module)
HS Code	8538.90 (typically declared for PLC I/O modules and parts)
Power Requirements	Supplied via S800 ModuleBus (nominal 5 VDC from the termination unit; module consumption typically < 3 W)
Dimensions & Weight	Approx. 120 × 45 × 110 mm; ~0.20 kg (module only)
Operating Temperature	0 to +55 °C; 5–95% RH, non‑condensing (typical for S800 I/O)
Signal Input/Output Types	Analog current inputs: 0/4–20 mA; commonly used with HART‑enabled transmitters for pass‑through diagnostics
Communication Interfaces	S800 ModuleBus via TU8xx termination units (system backplane bus)
Installation Method	DIN‑rail mounted on compatible S800 termination units (e.g., TU810, TU812, TU830 series)

Application Fields

The AI810 fits continuous and batch processes where robust current loops are standard. Typical use cases include:

• Oil & Gas: pressure/flow transmitters on separators, well pads, and custody transfer skids.
• Chemicals & Petrochem: reactor feed monitoring, utility flow metering, tank farm gauging.
• Water & Wastewater: level and pressure from lift stations, membrane plants, and clarifiers.
• Power Generation: condenser vacuum, fuel gas flow, and auxiliary system monitoring.
• Pulp & Paper: headbox pressure, chemical dosing skids, and pulp consistency measurement via 4–20 mA converters.

A maintenance lead at a refinery told us they swapped an AI810 into an existing S800 rail in under 10 minutes, including loop checks—the kind of real‑world speed that keeps turnarounds on schedule.

Advantages & Value

• Reliability – Proven module format with steady performance in electrically noisy environments.
• Compatibility – Seamless with AC 800M and 800xA engineering tools; supports standard S800 wiring practices.
• Lifecycle cost savings – Reduced commissioning effort and minimal retraining for technicians already familiar with S800 I/O.
• Serviceability – Front‑access terminals and straightforward diagnostics make routine work faster.
• Supply assurance – Suited as a like‑for‑like replacement, helping minimize engineering changes.

Installation & Maintenance

• Cabinet & mounting – Install on a compatible TU8xx termination unit mounted to a grounded DIN rail; allow space for ventilation and service access.
• Wiring – Use twisted, shielded pairs for 4–20 mA loops; land shields at a single point to avoid ground loops; verify loop power and polarity before energizing.
• Environment – Keep within specified temperature and humidity; avoid heavy vibration and corrosive atmospheres unless the panel is rated for it.
• Safety – De‑energize the loop before inserting/removing the module; follow site lockout/tagout procedures.
• Routine care – Periodically check terminal tightness, clean dust with dry air, and verify scaling/calibration in the control system. If HART is used, schedule device status scans and update instrument descriptors as needed.

Quality & Certifications

• CE marked; manufacturer’s quality system typically conforms to ISO 9001.
• UL/cUL and RoHS compliance are commonly met for S800 I/O modules; documentation available on request.
• Standard manufacturer warranty practices apply; we provide a 365‑day warranty on supply.

Common Supporting Components

For a tidy, reliable installation, these S800 accessories are frequently paired with AI810:

• TU810 / TU812 / TU830 series termination units – Provide the ModuleBus connection, DIN‑rail mounting, and field wiring terminations.
• TB820V2 ModuleBus extension – Optical link for longer I/O segments when spacing out cabinets.
• CI854A or CI851 communication interfaces – Depending on your controller network, for integrating S800 I/O with the AC 800M.

Need help confirming channel counts, HART setup, or a direct replacement package? Share your current S800 I/O layout or the termination unit model, and I’ll validate compatibility before you order.