Description
The ABB AI895, order code 3BSC690086R1, is an S800 I/O analog input module designed for process industries that standardize on 4–20 mA loops and want HART diagnostics without adding extra hardware. From my experience, this module fits well when you’re consolidating mixed transmitter brands and need stable, low-noise current acquisition with HART pass‑through to asset management tools. You might notice that it typically drops into existing S800 backplanes with minimal rework and keeps commissioning predictable.
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 payment; full payment prior to delivery
- Express options: FedEx, UPS, DHL
- Packing: Anti‑static protection and shock‑resistant outer carton, suitable for international air freight
- Traceability: Shipment photos and serial/label confirmation before dispatch on request
Key Features
- 8 analog input channels (4–20 mA) – Designed for standard process transmitters; stable conversion for control and historian use.
- HART support – Pass‑through for device configuration and diagnostics in most S800 setups, reducing handheld work in the field.
- Loop‑powered and externally powered transmitters – Typically supports both wiring strategies, which helps during brownfield migrations.
- Channel fault detection – Open‑circuit/short detection behavior commonly used for faster troubleshooting.
- S800 ModuleBus integration – Works within ABB S800 I/O with AC 800M or via remote I/O interfaces, keeping engineering consistent.
- Compact, DIN‑rail installation – Mounts on S800 terminal bases (TU8xx series), helping you keep cabinets neat.
- Group isolation concept – Galvanic isolation to the backplane; channels typically share a common return, which simplifies wiring in many cases.
Technical Specifications
| Brand / Model | ABB AI895 – 3BSC690086R1 (S800 I/O) |
| HS Code | 8537.10 (Programmable controller assemblies / I/O) |
| Power Requirements | Supplied via S800 ModuleBus/backplane (24 VDC system supply); module consumption is typically low (around 1–2 W) |
| Signal Input Types | 8 × analog inputs, 4–20 mA; HART FSK superimposed for device communication |
| HART Capability | HART pass‑through to asset tools via controller/engineering environment (channel‑based) |
| Communication Interfaces | S800 ModuleBus via terminal base; used with controllers (e.g., AC 800M) or remote I/O interfaces (e.g., CI8xx families) |
| Installation Method | DIN‑rail via S800 terminal bases (e.g., TU810, TU812, TU830 series), front‑removable module design |
| Operating Temperature | Typically 0 to +55 °C for standard S800 environments |
| Dimensions & Weight | S800 single‑width form factor (approx. 45 mm module width); compact, cabinet‑friendly |
Application Fields
The AI895 tends to be a solid fit in continuous and batch facilities where loop integrity and device diagnostics matter:
- Refining & petrochemicals – Pressure/level/flow transmitters with HART status for proactive maintenance.
- Chemicals & specialty chemicals – Mixed-vendor instrument fleets; easier device configuration through HART pass‑through.
- Power & utilities – Feedwater, boiler, and balance-of-plant loop monitoring with predictable scan behavior.
- Pulp & paper, food & beverage – Stable 4–20 mA acquisition where noise immunity and channel diagnostics are valued.
A maintenance engineer at a mid‑size chemical site mentioned that using AI895 channels for valve positioners and smart pressure transmitters “cut our start‑up tuning time because HART alerts surfaced early.”
Advantages & Value
- Reliability – Proven S800 I/O platform; modules are easy to swap without disturbing field wiring.
- Compatibility – Works within ABB AC 800M/800xA architectures and, in many cases, via remote I/O interfaces for other DCS hosts.
- Lifecycle savings – HART diagnostics can reduce site trips and unplanned downtime; channel density keeps cabinets compact.
- Support – Clear part number (3BSC690086R1) simplifies spares strategy and revision control.
Installation & Maintenance
- Panel & wiring – Mount on approved S800 terminal bases (e.g., TU810/TU812/TU830) on DIN rail; maintain good cable segregation for analog signals; shield and ground per ABB guidelines.
- Ventilation – Provide standard cabinet ventilation for S800 I/O; avoid hotspots near power supplies.
- Power & loops – Verify 24 VDC supply quality; for loop‑powered devices, check per‑channel current limits and any external barrier requirements.
- Safety – De‑energize before insertion/removal; follow site lock‑out/tag‑out; confirm HART polling does not interfere with critical loops.
- Routine care – Periodic terminal checks for tightness, clean dust with dry air, back up configuration, and keep controller/DTM packages updated when HART is used.
Quality & Certifications
- CE and RoHS compliance are typical for ABB S800 I/O series.
- UL/cUL listings are commonly available for S800 modules used in North America.
- Manufacturer warranty policies vary by region; ABB commonly provides a standard limited warranty (often 12 months). Our sales warranty is 365 days as stated above.
Related & Supporting Components (for smoother deployment)
- Terminal Bases: TU810, TU812, TU830 series (choose based on channel density and wiring style).
- Communication Interfaces: CI801 (PROFIBUS‑DP slave for remote S800 I/O), CI840A/CI854A families for AC 800M/800xA ModuleBus connectivity.
- Shielding & Accessories: ABB shield terminals and labeling kits to keep loop identification clear during maintenance.
If you’re replacing an existing S800 analog input card, the AI895 is usually a straight swap when HART is required on 4–20 mA loops. Send a quick photo of your current terminal base label and we can double‑check wiring compatibility before shipment.
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