ABB AI635
ABB AI635
ABB AI635
ABB AI635
ABB AI635

ABB AI635 3BHT300032R1 | Advant Master DCS Analog Signal Conditioner

  • Brand: ABB
  • Model: AI635 (3BHT300032R1)
  • Product Type: Analog Input Module
  • Series: Advant OCS (Open Control System)
  • Core Function: Acquires and conditions analog signals from field instruments; converts them to digital data for the controller.
  • Key Specs: 8-channel, 4-20mA/0-10V input; high accuracy (±0.1%).
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Part number: ABB AI635 3BHT300032R1
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Description

AI635 3BHT300032R1: Product Overview
The referenced component is an 8-channel analog input module designed for integration within ABB’s Advant Open Control System (OCS), a distributed control system (DCS) architecture. Its position in an automation system is to serve as a critical interface for acquiring analog signals from field-mounted instruments, such as pressure transmitters, temperature sensors, and flowmeters. It is typically mounted in an Advant I/O station, which can be located remotely from the main control room, forming a node in a distributed network that reduces the complexity of field wiring.
The core functionality involves signal conditioning, electrical isolation, and analog-to-digital conversion. The module processes differential input signals, which can be configured for 4-20mA current loops or 0-10V voltage levels. It performs linearization, filtering, and scaling of the raw signal before converting it to a 16-bit digital value. This processed data is then transmitted to the central controller via the Advant fieldbus for use in control logic, alarming, and historical trending.
This module belongs to the Advant OCS product family, a platform recognized for its modularity, scalability, and adherence to open system principles. The benefits of this platform include a significant reduction in field wiring through distributed I/O, simplified system expansion via plug-and-play modules, and a consistent engineering environment that streamlines configuration and maintenance. The platform’s design philosophy aims to lower the total cost of ownership and increase system availability for continuous process operations.

ABB AI635

ABB AI635

AI635 3BHT300032R1: Technical Specifications
  • Model Number: AI635 (3BHT300032R1)
  • Manufacturer: ABB
  • Product Type: 8-Channel Analog Input Module
  • Number of Channels: 8
  • Input Type: Differential (current or voltage)
  • Input Signal: 4-20mA, 0-20mA, 0-10V (software configurable)
  • Accuracy: ±0.1% of full scale
  • Resolution: 16-bit
  • Isolation: 500Vrms channel-to-channel and channel-to-backplane
  • Input Impedance: 250 ohms (for current input)
  • Power Supply: 24 V DC (from I/O station backplane)
  • Operating Temperature: 0°C to +55°C
  • Storage Temperature: -40°C to +70°C
  • Dimensions: 40 mm (width) x 273 mm (height) x 252 mm (depth)
  • Weight: Approximately 1.2 kg
Core Features & Customer Value​
The high channel density of eight inputs per module maximizes the use of available I/O rack space. For the engineer, this reduces the number of modules and carriers required, simplifying system architecture and lowering overall hardware costs. It also makes the wiring design more efficient, as multiple field transmitters can be terminated on a single module.
High accuracy and resolution are critical for precise process control. The ±0.1% accuracy and 16-bit resolution ensure that the digital representation of the analog signal is faithful to the actual process variable. For the end-user, this translates to tighter control loops, better product quality, and more reliable data for regulatory compliance and analysis.
Electrical isolation is a key feature that protects the control system from ground loops and high-voltage transients common in industrial environments. The 500Vrms isolation barrier between channels and to the backplane prevents noise-induced errors and equipment damage. For the maintenance team, this means enhanced system reliability and fewer nuisance trips, contributing to increased plant uptime.
The module’s design as part of the Advant OCS platform offers inherent advantages. The distributed nature of the I/O reduces the amount of copper wiring required, lowering installation costs. The modular, hot-swappable design simplifies maintenance, allowing a failed module to be replaced without shutting down the entire system, thus minimizing downtime.

ABB AI635

ABB AI635

Typical Applications​
In a steam power plant, this module is used to monitor the feedwater system. It acquires 4-20mA signals from flowmeters on the condensate pumps and level transmitters in the deaerator, providing the DCS with real-time data to control pump speeds and chemical dosing for optimal boiler feedwater chemistry.
Within a petrochemical refinery, the module is installed in a remote I/O station near a catalytic reformer unit. It interfaces with thermocouples and pressure transmitters to monitor reactor temperatures and hydrogen partial pressures, which are critical for maintaining catalyst activity and product yield.
In a municipal water treatment facility, the module acquires signals from pH sensors, turbidity meters, and chlorine analyzers in the filtration and disinfection stages. The accurate data is used to control chemical dosing pumps and adjust filter backwash cycles, ensuring treated water meets quality standards.

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