ABB AO815

Description

Detailed Parameter Table

ABB AO815

Product Introduction

The AO815 is a high-precision analog output module from ABB, designed as part of the S800 I/O system to interface with the AC800M controller. It converts digital control signals from the controller into proportional analog outputs (current or voltage), enabling precise regulation of field devices such as control valves, variable speed drives, and positioners in industrial processes.

With 4 isolated channels, each configurable for current (4-20 mA) or voltage (0-10 V, ±5 V, ±10 V) outputs, the AO815 offers exceptional flexibility for diverse control applications. Its 16-bit resolution and ±0.1% accuracy ensure tight control over processes requiring precise adjustments, such as flow rate regulation in chemical plants or temperature control in pharmaceutical reactors. The module’s robust diagnostics and wide operating temperature range (-40°C to +70°C) make it reliable in harsh industrial environments, while seamless integration with ABB’s automation ecosystem simplifies system design and commissioning.

Core Advantages and Technical Highlights

Multi-signal flexibility
Each channel of the AO815 can be independently configured for current or voltage output, eliminating the need for separate modules in mixed-signal systems. In a water treatment plant’s filtration system, this versatility allows the same module to:

Output 4-20 mA to control a proportional valve regulating water flow

Provide 0-10 V to adjust the speed of a backwash pump via a variable frequency drive (VFD)
This reduces hardware costs and saves DIN rail space in the control cabinet.

High accuracy and resolution
With 16-bit resolution (equivalent to 0.0015% of full scale) and ±0.1% accuracy, the AO815 delivers precise control in critical processes. In a semiconductor manufacturing cleanroom, it regulates the flow of ultra-pure gases with adjustments as small as 0.002 mA, ensuring gas concentrations remain within 0.1% of setpoints—critical for maintaining wafer quality.

Advanced diagnostics
The AO815 includes real-time monitoring of output drift, short circuits, and overcurrent conditions. In an oil refinery’s distillation column control system, short-circuit detection immediately identifies a damaged cable to a control valve, triggering an alarm and maintaining safe operation of other channels (e.g., those controlling heater elements). This targeted fault isolation minimizes process disruption.

Typical Application Scenarios

In a chemical processing plant’s batch reactor system:

AO815 modules control 4-20 mA signals to proportional control valves, regulating the addition of reactants.

Voltage outputs (0-10 V) adjust the speed of agitator motors, ensuring uniform mixing.

The AC800M controller uses feedback from AI815 input modules to adjust AO815 outputs, maintaining reactor pressure and temperature within tight tolerances.

Isolation between channels prevents cross-talk between corrosive chemical lines and solvent lines, ensuring accurate control of each reactant.

In a food and beverage plant’s pasteurization line:

AO815 outputs control the opening of steam valves (4-20 mA), regulating temperature in the pasteurization tunnel.

0-10 V outputs adjust conveyor speed, ensuring products receive the required 30-second exposure to 72°C temperatures.

Diagnostic features alert operators to a failing valve (e.g., increased current draw), allowing maintenance before under-pasteurized products are produced.

Paired with XVC769AE101 termination units, wiring from the module to field devices is organized, simplifying sanitization and inspection procedures.

ABB AO815

Related Model Recommendations

AI815: Analog input module that complements AO815 for closed-loop control in S800 systems.

TB820V2: Terminal base required for mounting AO815, providing secure connections for field wiring.

XVC769AE101: Termination unit that organizes analog signal wiring, compatible with AO815.

AC800M PM864: Controller that processes sensor data and sends setpoints to AO815 modules.

CI854A: Profibus DP communication module enabling remote monitoring of AO815 status.

AO880: 8-channel analog output module for larger systems, compatible with AO815 in distributed I/O networks.

Installation, Commissioning and Maintenance Instructions

Installation preparation
Mount the AO815 on a 35 mm DIN rail using the TB820V2 terminal base, ensuring 50 mm clearance for cooling. Connect 24 V DC auxiliary power to the terminal base, verifying correct polarity. Wire field devices to the output terminals using shielded twisted-pair cable (0.5-1.5 mm²) to minimize noise. For current outputs, ensure the total load resistance does not exceed 500 Ω; for voltage outputs, load impedance must be ≥10 kΩ. Ground cable shields at both ends to prevent interference.

Commissioning steps
Configure AO815 channels via Control Builder M software, setting output type (current/voltage), range, and scaling. Calibrate each channel using a precision multimeter and signal generator, verifying output accuracy at 0%, 50%, and 100% of full scale. Test fault conditions (e.g., short circuit) to confirm the module enters a safe state and logs the fault. Verify communication with the AC800M controller, ensuring setpoint changes are reflected accurately in output signals.

Maintenance suggestions
Inspect AO815 quarterly by checking status LEDs—green indicates normal operation, red indicates faults. Perform annual calibration to correct for drift, especially in temperature-critical applications. Clean terminal connections with compressed air to remove dust. If a channel fails calibration or exhibits erratic behavior, swap the device to a spare channel and reconfigure. Replace the module if multiple channels fail, using only ABB-approved spares configured to match the original’s settings.

Service and Guarantee Commitment

The AO815 is backed by a 3-year warranty, covering defects in materials and workmanship under normal operating conditions. ABB’s process automation technical support team provides guidance on calibration, configuration, and integration with AC800M systems, including compatibility with modules like AI815 and XVC769AE101.

Customers receive access to detailed calibration procedures and wiring diagrams specific to AO815. ABB offers factory calibration services for critical applications, ensuring traceability to international standards. With global distribution centers, replacement modules are available for rapid delivery, minimizing downtime in precision control processes.