ABB AI815

Description

Detailed Parameter Table

ABB AI815

Product Introduction

The AI815 is a flagship analog input module from ABB, engineered for the S800 I/O system to deliver exceptional measurement accuracy in critical industrial processes. As a premium component in ABB’s automation portfolio, it converts analog signals from sensors (e.g., pressure transmitters, thermocouples, RTDs) into high-resolution digital data for the AC800M controller, enabling precise process control and monitoring.

With 8 differential channels supporting a wide range of industrial signals, the AI815 is versatile enough to handle diverse applications—from pharmaceutical batch processing (where 0.1°C temperature accuracy is critical) to chemical reactor monitoring (requiring stable 4-20 mA pressure readings). Its 24-bit resolution and 5 kV isolation ensure reliable performance even in electrically noisy environments, making it a cornerstone of high-precision automation systems. Whether integrated into new installations or retrofitted into existing S800 networks, the AI815 sets the standard for analog measurement in industrial automation.

Core Advantages and Technical Highlights

Ultra-High Measurement Precision

The AI815’s 24-bit resolution and ±0.05% accuracy capture minute signal variations that standard modules miss. In a semiconductor cleanroom, it detects 0.02% fluctuations in 4-20 mA flow signals from gas delivery systems, ensuring wafer fabrication environments remain within strict process tolerances. For Pt100 temperature measurements, its ±0.1°C accuracy prevents costly defects in temperature-sensitive processes like adhesive curing.

Multi-Signal Compatibility

A single AI815 module can simultaneously handle thermocouples, RTDs, and voltage/current signals, eliminating the need for specialized modules. In a food processing plant, it monitors:

K-type thermocouples (oven temperatures)

4-20 mA from pressure transmitters (pumping systems)

±10 V from load cells (ingredient weighing)
This flexibility reduces cabinet space requirements and simplifies spare parts inventory.

Robust Noise Immunity

5 kV AC isolation between channels and the system bus protects against electromagnetic interference (EMI) and ground loops. In a steel mill—where arc furnaces generate intense electrical noise—the AI815 maintains stable readings from vibration sensors, preventing false alarms and ensuring continuous casting operations run smoothly.

ABB AI815

Typical Application Scenarios

Pharmaceutical Manufacturing

In a bioreactor control system, the AI815 monitors critical parameters:

Pt100 RTDs (bioreactor temperature, ±0.1°C accuracy required for cell growth)

4-20 mA from pH transmitters (culture medium acidity)

0-10 V from dissolved oxygen sensors
Data from the module is sent to the AC800M controller, which adjusts heating elements and gas flow via analog output modules. The AI815’s precision ensures compliance with FDA regulations for process validation.

Power Plant Turbine Monitoring

The AI815 plays a key role in turbine health management:

Thermocouples (R-type) measure exhaust gas temperatures (up to 1,000°C)

4-20 mA from pressure transducers (oil system pressure)

±10 V from vibration accelerometers
Its high sampling rate (40 Hz) captures transient conditions during startup/shutdown, enabling predictive maintenance to avoid unplanned downtime.

Related Model Recommendations

AO810V2: Analog output module that pairs with the AI815 in closed-loop control systems (e.g., adjusting valves based on temperature readings).

TB820V2: Terminal base for the AI815, featuring screw terminals for sensor wiring and DIN rail mounting.

AC800M PM864: Controller that processes AI815 data to execute control logic.

1SVR011718R2500: 24 V DC power supply to energize the module and loop-powered sensors.

CM579-PNIO: Profinet communication module that enables remote monitoring of AI815 data in distributed systems.

SPDSO14: Digital output module for triggering alarms based on AI815 overrange conditions.

Installation, Commissioning, and Maintenance

Installation Steps

Mount the TB820V2 terminal base on a 35 mm DIN rail, leaving 20 mm clearance for airflow.

Connect sensor wiring (shielded twisted-pair recommended) to terminals, matching signal types to channel configurations.

Attach the AI815 to the terminal base until it clicks into place; secure with locking clips.

Power the module via 24 V DC (use a regulated supply like the 1SVR011718R2500) and configure signal types/ranges via Control Builder M software.

Maintenance Guidelines

Daily Checks: Verify green power LED and absence of fault LEDs. Use HMI to confirm signal stability.

Quarterly Calibration: Use a precision calibrator (e.g., Fluke 725) to verify accuracy, especially in regulated industries.

Troubleshooting: If a channel drifts, check for loose wiring or sensor faults. Replace the module if calibration fails—ABB’s “hot-swap” design allows replacement without powering down the S800 rack.

Service and Guarantee Commitment

The AI815 comes with a 3-year warranty covering defects in materials and workmanship. ABB’s technical support provides specialized guidance for high-precision applications, including thermocouple cold-junction compensation and RTD lead-wire resistance correction.