ABB AI810 3BSE008516R1

Description

Detailed Parameter Table

ABB AI810 3BSE008516R1

Product introduction

The AI810 3BSE008516R1 is a high-performance analog input module from ABB, designed to accurately measure and convert a wide range of analog signals from field devices into digital data for the AC800M controller in industrial automation systems. As a key component of the S800 I/O family, it serves as the “sensory interface” of the automation system, capturing critical process variables such as temperature, pressure, flow, and level from sensors and transmitters.

This module integrates seamlessly with ABB’s AC800M controller and relies on terminal bases like the TB820V2 for secure wiring connections to field devices. With 8 configurable channels, each capable of accepting signals from 4-20 mA transmitters, voltage sources, thermocouples, or RTDs, the AI810 3BSE008516R1 offers exceptional versatility—eliminating the need for multiple specialized modules in complex systems.

Built to withstand harsh industrial environments, the AI810 3BSE008516R1 features robust channel-to-channel isolation and wide temperature tolerance, ensuring reliable operation in settings like chemical plants, power stations, and manufacturing facilities. Its plug-in design simplifies installation and maintenance, while advanced diagnostics minimize downtime by quickly identifying issues such as sensor failures or wiring faults.

Core advantages and technical highlights

Multi-signal compatibility

The AI810 3BSE008516R1 supports an extensive range of input signals, including 4-20 mA, voltage, thermocouples, and RTDs, with each channel configurable independently. In a food processing plant, for example, one channel can measure oven temperature via a type K thermocouple, another can monitor pressure via a 4-20 mA transmitter, and a third can track flow via a 0-10 V sensor—all on a single module. This flexibility surpasses that of the AO801 (which focuses solely on outputs) and reduces system complexity.

High-precision measurement

With ±0.1% accuracy for standard signals and ±0.2°C precision for Pt100 RTDs, the AI810 3BSE008516R1 delivers reliable data for critical processes. In pharmaceutical manufacturing, this precision ensures that fermentation temperatures are measured within ±0.3°C, maintaining optimal conditions for microbial growth. The module’s 16-bit resolution captures subtle signal variations, such as small pressure fluctuations in a gas pipeline, which could indicate leaks.

Enhanced isolation and noise immunity

The AI810 3BSE008516R1 features 2.5 kV AC isolation between channels and from channels to the bus, preventing ground loops and electromagnetic interference (EMI) from distorting measurements. In a steel mill, where heavy machinery generates significant EMI, this isolation ensures accurate readings from temperature sensors near induction furnaces—something that unisolated modules might struggle with.

Comprehensive diagnostics

Equipped with LED indicators and advanced fault detection, the AI810 3BSE008516R1 provides real-time insights into system health. If a thermocouple connected to channel 5 fails, the module flags the issue with a red LED and transmits a fault code to the AC800M controller, enabling predictive maintenance. This diagnostic capability is critical in oil refineries, where unplanned shutdowns due to undetected sensor failures can cost millions.

ABB AI810 3BSE008516R1

Typical application scenarios

In a water treatment plant, the AI810 3BSE008516R1 acts as the primary data collection hub for process variables. Connected to the TB820V2 terminal base, it monitors:

• 4-20 mA signals from flow meters in filtration systems
• Pt100 RTDs measuring water temperature in storage tanks
• 0-10 V outputs from pH sensors in chemical dosing tanks
• ±10 V signals from level transmitters in sedimentation basins

The module transmits this data to the AC800M controller, which uses it to adjust valves (via the AO801 analog output module) and optimize chemical dosing. The AI810 3BSE008516R1‘s 8 channels eliminate the need for multiple modules, reducing cabinet space and wiring complexity.

In a power generation facility, the module integrates with the CI810B 3BSE020520R Profibus module to send real-time data to a SCADA system. It measures steam pressure (4-20 mA), turbine bearing temperatures (RTDs), and generator voltage (0-10 V), enabling operators to monitor equipment health and prevent failures.

Related model recommendations

• AI830 3BSE008553R1: A 4-channel high-speed analog input module with a 100 Hz sampling rate, ideal for dynamic processes requiring faster data capture than the AI810 3BSE008516R1.
• AO801: An analog output module that, when paired with the AI810 3BSE008516R1, forms a closed-loop control system—e.g., measuring tank level with the AI810and adjusting a valve via the AO801.
• TB820V2: A terminal base that provides secure wiring connections for the AI810 3BSE008516R1, enabling plug-and-play installation and easy maintenance.
• TC514V2 3BSE013281R1: A dedicated temperature controller module that complements the AI810 3BSE008516R1in systems requiring specialized thermal control alongside general analog measurements.
• 3BHE009017R0102: A power supply module that delivers stable 24 V DC to the AI810 3BSE008516R1and connected terminal base, ensuring reliable operation.
• CI801: A Modbus communication module that transmits data from the AI810 3BSE008516R1to legacy Modbus systems, bridging new and old automation infrastructure.

Installation, commissioning and maintenance instructions

Installation preparation

Before installing the AI810 3BSE008516R1, ensure the control cabinet is clean, dry, and free from conductive debris. The ambient temperature must be within -25°C to +70°C, with relative humidity ≤95% (non-condensing). Required tools include a screwdriver, wire strippers, a multimeter, and a thermocouple/RTD calibrator.

Mount the TB820V2 terminal base on a 35 mm DIN rail, then plug the AI810 3BSE008516R1 into the base until it clicks into place. For sensor connections:

• Use shielded twisted-pair cables (0.5-1.5 mm²) for analog signals
• Ground shields at both ends to minimize noise
• Separate high-voltage wiring from low-voltage sensor cables to avoid interference

Connect the 24 V DC power supply (from 3BHE009017R0102) to the terminal base, verifying polarity. Configure channel types (e.g., 4-20 mA, type K thermocouple) via the AC800M controller software before powering on.

Maintenance suggestions

For daily maintenance, check the AI810 3BSE008516R1‘s LEDs: a steady green power LED and flashing green channel LEDs indicate normal operation. A red fault LED signals issues like open circuits or overrange signals—refer to the user manual for channel-specific codes.

Calibrate the module annually using a precision signal generator and reference thermometer (for RTD/thermocouple channels). This is especially critical in applications like semiconductor manufacturing, where measurement drift could affect product quality.

Inspect terminal connections quarterly for corrosion or looseness, which can cause signal degradation. Clean the module with compressed air to remove dust; avoid liquids. If a channel fails, swap sensors between channels to isolate the issue—if the fault follows the sensor, replace the field device; otherwise, replace the module.

Service and guarantee commitment

The AI810 3BSE008516R1 is backed by ABB’s 3-year warranty, covering defects in materials and workmanship under normal operating conditions. During the warranty period, ABB will repair or replace faulty modules at no cost, minimizing downtime.

ABB’s technical support team provides 24/7 assistance for installation, configuration, and troubleshooting, including guidance on integrating the AI810 3BSE008516R1 with the AC800M controller, AO801 output module, and TB820V2 terminal base. We offer detailed calibration procedures and wiring diagrams to ensure optimal performance.

Extended service contracts are available, including on-site calibration, priority support, and software updates. ABB’s global network ensures fast delivery of replacement modules, reducing disruptions in critical applications. Trust the AI810 3BSE008516R1 to deliver accurate, reliable data—backed by ABB’s expertise in industrial automation.