ABB AI930

Description

Detailed Parameter Table

ABB AI930

Product introduction

The AI930 is a high-precision analog input module from ABB, engineered to capture and convert complex analog signals from field devices into high-resolution digital data for the AC800M controller in industrial automation systems. As an advanced member of the S800 I/O family, it serves as a critical “measurement hub” for capturing demanding process variables such as high-speed pressure fluctuations, precise temperature gradients, and microvolt-level sensor signals—applications where standard modules may lack sufficient accuracy or speed.

This module integrates seamlessly with ABB’s AC800M controller and relies on terminal bases like the TB820V2 for secure wiring to field devices. With 4 configurable channels supporting a broad range of signals (from 4-20 mA transmitters to thermocouples and RTDs), the AI930 excels in applications requiring both high accuracy and fast response, such as aerospace testing facilities, semiconductor fabrication, and precision chemical processing.

Built with industrial-grade components, the AI930 features enhanced isolation (5 kV AC) and wide temperature tolerance, ensuring reliable operation in electrically noisy environments. Its 24-bit resolution and 100 Hz sampling rate make it ideal for capturing subtle signal variations that standard modules might miss. Unlike the FENA-11 (which focuses on Ethernet communication), the AI930 specializes in high-fidelity analog measurement, providing the detailed data needed for advanced process control.

Core advantages and technical highlights

Ultra-high accuracy and resolution

The AI930 delivers ±0.05% accuracy (at 25°C) and 24-bit resolution, making it suitable for applications where precise measurement is critical. In pharmaceutical manufacturing, for example, it can monitor reactor temperatures via Pt100 RTDs with ±0.1°C precision, ensuring compliance with strict regulatory standards. This level of accuracy surpasses standard analog input modules (which typically offer ±0.1% accuracy), enabling tighter process control and reducing product variability.

High-speed sampling

With a 100 Hz sampling rate (configurable up to 500 Hz), the AI930 captures rapid signal changes, such as pressure spikes in hydraulic systems or transient temperature fluctuations in laser machining. In automotive testing, it can record vibration patterns from strain gauges at 500 samples per second, providing engineers with detailed data to optimize vehicle performance. This speed is significantly faster than modules like the AI810, making it ideal for dynamic processes.

Enhanced isolation and noise immunity

The AI930 features 5 kV AC isolation between channels and from channels to the bus, eliminating ground loops and rejecting electromagnetic interference (EMI) from nearby motors or power lines. In steel mills or welding facilities—where EMI levels are high—this isolation ensures stable readings from sensitive sensors, such as microvolt-level thermocouples measuring furnace temperatures. The module’s advanced filtering options further reduce noise, ensuring clean data even in harsh electrical environments.

Flexible channel configuration

Each of the AI930‘s 4 channels can be independently configured for different signal types, allowing mixed-use in complex systems. For example, in a research laboratory, one channel can measure a 4-20 mA flow signal, another a type S thermocouple (for high-temperature measurements), a third a ±10 V strain gauge output, and the fourth a Pt100 RTD—all on a single module. This flexibility reduces the need for multiple specialized modules, simplifying system design.

ABB AI930

Typical application scenarios

In a semiconductor fabrication plant, the AI930 is used to monitor critical process variables in chemical vapor deposition (CVD) chambers. Connected to the TB820V2 terminal base, it measures:

• Gas flow rates via 4-20 mA mass flow controllers (±0.05% accuracy ensures precise gas mixture ratios)
• Chamber temperature via type R thermocouples (±0.1°C precision maintains uniform film deposition)
• Vacuum pressure via 0-10 V transducers (high-speed sampling captures pressure transients during pump-down)

The module transmits this high-resolution data to the AC800M controller, which adjusts heater power (via AO801 modules) and gas valves (via DO910 modules) to maintain optimal CVD conditions. The AI930‘s noise immunity is critical here, as even small measurement errors could result in defective wafers costing thousands of dollars.

In a wind turbine control system, the AI930 monitors vibration, oil temperature, and generator current. Its high-speed sampling captures vibration harmonics that indicate bearing wear, while its accuracy ensures precise current measurement for efficiency calculations. Data from the AI930 is sent to the turbine controller, which uses the FENA-11 Ethernet adapter to transmit performance metrics to a central SCADA system for fleet-wide monitoring.

Related model recommendations

• AI830 3BSE008553R1: An 8-channel high-speed analog input module with 16-bit resolution, suitable for applications requiring more channels than the AI930but with slightly lower precision.
• TB820V2: A terminal base that provides secure wiring connections for the AI930, enabling plug-and-play installation and shielded sensor connections.
• AO801: An analog output module that works with the AI930in closed-loop control systems—e.g., adjusting a valve based on pressure readings from the AI930.
• FENA-11: An Ethernet adapter that transmits data from the AC800M controller (processing AI930inputs) to remote monitoring systems, enabling centralized data analysis.
• CI810B 3BSE020520R: A Profibus DP module that integrates AI930data into Profibus networks, complementing the FENA-11 in hybrid communication setups.
• 3BHE009017R0102: A power supply module that delivers stable 24 V DC to the AI930and terminal base, ensuring measurement accuracy is not compromised by voltage fluctuations.

Installation, commissioning and maintenance instructions

Installation preparation

Before installing the AI930, 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 torque screwdriver, wire strippers, and a precision calibrator (for commissioning).

Mount the TB820V2 terminal base on a 35 mm DIN rail, then plug the AI930 into the base until it clicks into place. Use shielded twisted-pair cables (0.5-1.5 mm²) for sensor connections, with shields grounded at both ends to minimize noise. Separate high-voltage wiring from low-voltage sensor cables by at least 100 mm to avoid interference.

Connect the 24 V DC power supply (from 3BHE009017R0102) to the terminal base, verifying polarity. Configure channel types, ranges, and filtering via the AC800M controller software before powering on.

Commissioning steps

After installation, calibrate the AI930 using a traceable precision calibrator. For each channel:

1. Apply a 0% span signal (e.g., 4 mA for a 4-20 mA input) and record the reading.
2. Apply a 100% span signal (e.g., 20 mA) and verify accuracy within ±0.05%.
3. Test mid-range values to ensure linearity.

For thermocouple channels, verify cold-junction compensation accuracy using a reference thermometer. Configure sampling rates and filtering based on application needs—use higher rates for dynamic signals (e.g., vibration) and stronger filtering for noisy environments.

Maintenance suggestions

For daily maintenance, check the AI930‘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 semi-annually (or annually in less critical applications) using a certified calibrator. This is especially important in regulated industries like pharmaceuticals, where measurement accuracy is audited.

Inspect terminal connections quarterly for corrosion or looseness, which can introduce measurement errors. Clean the module with compressed air to remove dust; avoid liquids. If a channel fails, swap sensors between channels to isolate the issue—replace the module if internal faults are confirmed, ensuring the replacement is configured to match the original settings.

Service and guarantee commitment

The AI930 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 in critical applications.

ABB’s technical support team provides 24/7 assistance for installation, calibration, and troubleshooting, including guidance on integrating the AI930 with the AC800M controller, FENA-11 Ethernet adapter, and TB820V2 terminal base. We offer detailed calibration procedures and application notes for high-precision scenarios.

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 applications where measurement accuracy is mission-critical. Trust the AI930 to deliver reliable, high-fidelity analog data—backed by ABB’s expertise in industrial automation.