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Product Introduction
The ABB AI635 (3BHT300032R1) is a robust and high-performance analog input module that forms a critical part of the ABB Symphony Plus and Freelance DCS systems, specifically within the Advant Controller 800 Series. Designed to deliver precise and reliable measurement of analog signals, the AI635 supports a range of standard industrial input types including voltage and current.
This module features 8 analog input channels, with each channel individually configurable for different signal types. It supports HART protocol, allowing not only signal measurement but also digital communication with smart field devices. The AI635’s design emphasizes redundancy, fault tolerance, and diagnostics, making it suitable for mission-critical process automation tasks.
Engineered to meet the demanding needs of industries such as power generation, petrochemical, and water treatment, the AI635 integrates seamlessly with ABB’s control systems to ensure reliable plant operation and efficient engineering.
Product Specifications
| Parameter | Details |
|---|---|
| Product Code | 3BHT300032R1 |
| Model Name | AI635 |
| Type | Analog Input Module |
| Number of Channels | 8 Analog Input Channels |
| Input Signal Types | 0–20 mA, 4–20 mA, ±10 V |
| HART Protocol Support | Yes (HART 5 and 7 supported on all channels) |
| Resolution | 16-bit |
| Accuracy | ±0.1% full scale |
| Input Impedance | ≥ 250 Ohms (current), ≥ 10 MΩ (voltage) |
| Isolation | Galvanic isolation between channels and system |
| Diagnostics | Channel fault detection, HART communication diagnostics |
| Redundancy Support | Yes (when used with redundant controllers and communication modules) |
| Mounting Type | DIN Rail or Module Base Mounting |
| Operating Temperature Range | 0°C to +70°C |
| Storage Temperature Range | -40°C to +85°C |
| Humidity | 5% to 95% non-condensing |
| Protection Class | IP20 |
| Dimensions (W x H x D) | 252 x 273 x 40 mm |
| Weight | 1.21 kg |
| Certifications | CE, cULus, RoHS, EN 61010-1, IEC 61131-2 |
| System Compatibility | ABB Advant Controller 800, Symphony Plus, Freelance |
Applications
The AI635 module is engineered for diverse industrial automation and process control applications. Its ability to handle analog signals with high precision and integrate HART-capable devices makes it especially valuable in the following industries:
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Power Generation – Monitoring turbine instrumentation, pressure, and flow sensors.
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Oil and Gas – Reliable signal acquisition from remote sensors in harsh environments.
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Chemical and Petrochemical – Measurement of critical process variables like temperature, level, and flow.
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Water and Wastewater Treatment – Accurate input from pH, flow, and conductivity transmitters.
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Mining and Metals – Robust data collection from vibration sensors, strain gauges, and control valves.
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Pulp and Paper – Monitoring of process quality and machine efficiency.
Advantages
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High Signal Accuracy: With 16-bit resolution and a 0.1% full-scale accuracy, the AI635 ensures extremely precise signal processing.
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HART Compatibility: Enables two-way digital communication for configuration, diagnostics, and status reporting of smart transmitters.
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Redundant System Integration: Fully supports redundant system topologies, improving plant availability and operational safety.
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Flexible Signal Handling: Accepts both current and voltage inputs, allowing integration with a broad range of sensors.
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Comprehensive Diagnostics: Built-in fault detection and HART diagnostics enhance reliability and simplify troubleshooting.
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Robust Environmental Design: Suitable for high-temperature industrial environments with excellent mechanical resilience.
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Modular and Scalable: Integrates seamlessly with ABB’s modular DCS architecture, enabling flexible and scalable system design.
Frequently Asked Questions (FAQ)
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What signal types are supported by the AI635 module?
It supports 0–20 mA, 4–20 mA, and ±10 V analog input signals. -
Does the AI635 support HART communication?
Yes, all 8 channels support HART protocol (HART 5 and HART 7). -
Can the AI635 module detect channel failures?
Yes, it includes built-in diagnostics that detect input signal faults and communication errors. -
Is this module suitable for redundant configurations?
Absolutely. The AI635 can be deployed in redundant controller and communication module setups. -
How is the module mounted?
The AI635 can be mounted via DIN rail or module base depending on system requirements. -
What is the accuracy level of the analog inputs?
The module offers ±0.1% full-scale accuracy, ensuring precise measurements. -
Can this module operate in high-temperature environments?
Yes, its operating temperature range is 0°C to +70°C, ideal for most industrial settings. -
Is the module isolated?
Yes, it provides galvanic isolation between each channel and the system bus. -
What tools are used for configuring the AI635?
ABB’s Control Builder or Freelance Engineering tools are commonly used for configuration. -
Can I use the AI635 with other brands of DCS systems?
The AI635 is designed for ABB systems. Integration with non-ABB systems is not standard and may require custom engineering.
Related Models from the Same Series or Application
| Model | Description | Channels | Protocol Support |
|---|---|---|---|
| AI630 3BHT300029R1 | Analog Input Module, standard inputs | 8 | No HART |
| AI620 3BHT300017R1 | Analog Input Module, basic functionality | 4 | No HART |
| AI801 3BSE020512R1 | S800 I/O Series, Analog Input | 8 | HART Supported |
| AI815 3BSE052604R1 | S800 I/O Analog Input with high isolation | 4 | Yes |
| DI830 3BSE013252R1 | S800 Digital Input Module | 16 | N/A |
| AO845A 3BSE045584R1 | S800 Analog Output Module | 8 | HART Supported |
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