Excellent PLC
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Product Overview
The ABB AI581-S (part number 1SAP282000R0001) is a Safety Analog Input Module designed for integration into ABB’s AC500-S Safety PLC platform. This module is engineered for SIL 3 (IEC 61508) and PL e (ISO 13849-1) compliant systems, offering high-integrity monitoring of analog process signals such as 0–20 mA or 4–20 mA loops. It is ideal for critical safety-related applications where secure, redundant, and reliable input acquisition is required.
The AI581-S module features 2 individually monitored analog channels, each capable of diagnosing signal integrity, wire break detection, and out-of-range conditions. It is fully compatible with the AC500 PLC family’s PROFINET/PROFIsafe communication architecture and can be deployed in a broad range of functional safety automation environments.
Key Features
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2-channel analog input for 0–20 mA and 4–20 mA signals
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Designed for SIL3 / PL e safety functions
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Short-circuit and wire-break detection
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HART transparency (read-through) supported
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Supports diagnostic data via PROFIsafe
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Fault-tolerant design with cyclic redundancy check (CRC)
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LED indicators for channel and fault status
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Compatible with AC500-S safety CPU via safety network
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Certified to IEC 61508, ISO 13849-1, IEC 62061
Technical Specifications
| Parameter | Specification |
|---|---|
| Channels | 2 safety analog input channels |
| Input Signal Range | 0–20 mA / 4–20 mA |
| Resolution | 16-bit |
| Diagnostic Features | Short-circuit, wire break, out-of-range detection |
| HART Support | Transparent read-through (non-safety critical use only) |
| Voltage Drop (per channel) | ≤ 2 V |
| Input Impedance | ≤ 250 Ω |
| Isolation | Channel-to-bus and channel-to-channel galvanic isolation |
| Operating Voltage | Supplied via system bus |
| Operating Temperature | -25°C to +60°C |
| Storage Temperature | -40°C to +85°C |
| Relative Humidity | 5% to 95%, non-condensing |
| Dimensions | 62 × 76 × 67.5 mm |
| Weight | 0.125 kg |
| Mounting Type | DIN rail (35 mm) |
| Safety Integrity Level | SIL3 (IEC 61508), PL e (ISO 13849-1), Cat. 4 |
| Certifications | CE, cULus, TÜV, SIL3, PL e, ATEX, IECEx |
Product Advantages
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Functional Safety Compliance: Certified to the highest industrial safety standards (SIL3/PL e).
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Dual-channel Design: Independent signal acquisition for critical redundancy and safety control.
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Reliable Diagnostics: Built-in monitoring for signal loss, short circuits, and performance degradation.
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Flexible Signal Compatibility: Handles standard current-loop signals used in industrial sensors.
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Transparent HART Communication: Enables access to smart sensor data without compromising safety.
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Seamless Integration: Part of the ABB AC500-S ecosystem with PROFIsafe communication.
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Compact Design: Slim 35 mm housing fits densely populated safety systems.
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LED Feedback: Quick and visual confirmation of input and fault states.
Industry Applications
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Emergency shutdown systems (ESD)
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Burner management and fuel control systems
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Chemical and petrochemical safety monitoring
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Pharmaceutical manufacturing and cleanroom environments
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Power generation and turbine protection
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Water/wastewater treatment with critical process control
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Mining and heavy machinery interlock systems
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Oil & gas production, including offshore safety modules
Frequently Asked Questions (FAQ)
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Q: What types of input signals are supported by AI581-S?
A: It supports 0–20 mA and 4–20 mA analog current signals. -
Q: Is the AI581-S suitable for SIL3 applications?
A: Yes, it is certified for SIL3 according to IEC 61508 and PL e per ISO 13849-1. -
Q: How many channels are available?
A: It has two independent analog input channels. -
Q: Can the AI581-S detect wiring faults?
A: Yes, it includes wire-break, short-circuit, and out-of-range diagnostics. -
Q: Does it support HART communication?
A: Yes, HART data can be read transparently for diagnostic purposes (non-safety critical). -
Q: How is the module powered?
A: Power is supplied via the AC500 system bus; no separate power input is required. -
Q: What type of mounting does the module support?
A: It is DIN-rail mounted (35 mm rail standard). -
Q: Can I use this module in hazardous environments?
A: Yes, it holds ATEX and IECEx certifications for use in explosive atmospheres. -
Q: Is it compatible with non-safety AC500 modules?
A: The AI581-S must be used in safety-certified configurations with AC500-S CPUs. -
Q: What is the module’s width?
A: It is 67.5 mm wide, making it suitable for high-density panel installation.
Related or Compatible Models (Same Series)
| Model | Description |
|---|---|
| AI581 | Standard analog input module (non-safety) |
| DI581-S | 8-channel digital safety input module for AC500-S systems |
| DO581-S | 8-channel safety-rated digital output module |
| AC500-S PM595-4ETH | Safety PLC CPU with extended communication interfaces |
| CI581-PN | PROFINET communication module for AC500 PLC systems |
| TU582-S | Safety terminal unit for AI/DI/DO modules |
Popular ABB Models (Same Brand)
| Model | Description |
|---|---|
| AI835A | Analog input module for S800 I/O, 4–20 mA, 8-channel |
| DI825 | 16-channel digital input module, S800 I/O series |
| PM867 | Redundant communication module for AC 800M controller |
| CI854AK01 | Profibus-DP interface module for AC 800M |
| PM564-RP | Compact AC500 PLC CPU with onboard I/Os and Ethernet |
| AI810 | 8-channel analog input module, 4–20 mA or 0–10 VDC |
