ABB AI815 (3BSE052604R1) – S800 I/O Analog Input Module for reliable 4–20 mA signal acquisition

The ABB AI815, order code 3BSE052604R1, is an analog input module from the S800 I/O family, designed for clean, stable acquisition of process signals in distributed control systems. From my experience, it fits best where you need dependable current-loop measurements from field transmitters—think flow, pressure, level, and temperature transmitters in 4–20 mA. It drops onto an S800 terminal unit, ties into the ModuleBus, and just works. You might notice that commissioning typically goes faster because wiring is straightforward and diagnostics are consistent across the S800 range.

Company’s Order Placement Process and Guarantees

• Warranty: 365 days from delivery
• 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
• Each unit is function-checked prior to dispatch, with traceable packing and ESD-safe handling

Key Features

• Designed for S800 I/O – Mounts on S800 terminal units (TU8xx series) and communicates via the ModuleBus.
• Industrial analog inputs – Typically used for 4–20 mA current-loop measurements from process transmitters.
• Stable, low-noise acquisition – ABB’s S800 signal chain is known for robust EMC behavior in noisy cabinets.
• Channel diagnostics – Supports standard S800 diagnostics for easier troubleshooting and maintenance.
• DIN-rail convenience – Tool-less module replacement on the terminal unit; minimal downtime.
• System compatibility – Integrates with ABB 800xA/AC 800M-based systems using S800 I/O architecture.

Technical Specifications

Note: Channel count, detailed ranges, and HART passthrough support can vary by S800 module type. If you need exact per-channel specifications for your DCS revision, send the system bill of materials and we’ll verify compatibility before shipping.

Application Fields

• Oil & Gas – Wellhead and separator skid instrumentation (pressure, DP flow, level transmitters).
• Chemicals & Petrochem – Reactor, column, and utility loops where 4–20 mA is standard.
• Power & Utilities – Boiler feedwater, condensate, and balance-of-plant measurements.
• Water & Wastewater – Pump station and treatment process monitoring with remote I/O cabinets.
• Pulp & Paper / Mining – Distributed cabinets in harsh EMC environments; S800 modules hold up well.

Advantages & Value

• Reliability – The S800 platform is mature; nuisance trips and noise issues are rare in properly grounded panels.
• Compatibility – Pairs with ABB AC 800M/800xA architectures using S800 I/O without rework of the ModuleBus.
• Lifecycle cost – Easy hot-swap on the terminal unit reduces downtime and technician hours.
• Traceable supply – We source by exact order code (3BSE052604R1), which typically simplifies validation in regulated plants.

A maintenance lead at a power plant told us the swap time for an AI815 was “under 5 minutes” because wiring stays on the terminal unit—seems small, but that saves a lot during outages.

Installation & Maintenance

• Panel standards – Install in a ventilated cabinet, DIN rail mounted, with proper PE/grounding and segregation from high-voltage lines.
• Terminal units – Use matching S800 terminal units (e.g., TU810, TU812, TU814, TU830/TU832 depending on wiring needs). The module snaps onto the TU; field wires do not move when you replace the module.
• Wiring – Use shielded twisted pair for analog loops; ground shields at one end. Keep analog and power cables routed separately.
• Safety – De-energize the backplane or follow hot-swap procedures specified by ABB. Observe ESD precautions.
• Routine care – Periodically check terminal tightness, clean dust with dry air, and verify channel calibration against a traceable source.
• Firmware/config – In most cases, configuration is done in the DCS engineering tool; keep backup of I/O allocation and channel scaling.

Quality & Certifications

• CE compliant
• UL listed/recognized, typically for industrial control equipment
• RoHS compliance for hazardous substances
• Manufactured under ISO 9001 quality systems
• Manufacturer’s warranty as per ABB policy; our supply warranty is 365 days

Recommended Supporting Components

• S800 Terminal Units: TU810 / TU812 / TU814 for standard wiring, TU830 / TU832 for compact/high-density terminals.
• S800 Power and Communication: Appropriate ModuleBus interfaces and redundant power modules as per your AC 800M/800xA design.
• Shielded Analog Cable: 2-wire twisted pairs, instrument grade, with proper drain wire termination.