Description
Detailed Parameter Table
| Parameter Name | Parameter Value |
| Product Model | AI02J |
| Manufacturer | ABB |
| Product Category | Analog Input Module |
| Channels | 2 isolated channels |
| Signal Ranges | 4-20 mA, 0-10 V, ±10 V |
| Resolution | 16-bit (0.0015% FS accuracy) |
| Update Rate | 10 ms per channel |
| HART Support | Protocol 7 (native pass-through) |
| Isolation | 1500 V AC channel-to-channel/field |
| Power Consumption | 1.2 W (24 VDC ±10%) |
| Operating Temperature | -25°C to +70°C |
| Certifications | CE, UL, IEC 61010-1 |
| Connection Type | Removable screw terminals |
| Dimensions (H×W×D) | 115 × 23 × 110 mm |
ABB AI02J
Product Introduction
The ABB AI02J is a high-density analog input module for ABB’s Compact 800 series I/O system, delivering precision signal acquisition in distributed control architectures. Designed for seamless integration with controllers like the PM861, this dual-channel module converts field instrument signals into process values with laboratory-grade accuracy. The AI02J features automatic sensor type detection and supports simultaneous HART 7 communication for smart device diagnostics without additional hardware.
As part of ABB’s S800 I/O family, the module operates in harsh environments like cement plants and offshore platforms, where its conformal-coated PCB withstands corrosive atmospheres. The ABB AI02J enables predictive maintenance through embedded diagnostics that detect open circuits, short circuits, and signal drift before they impact process stability. Its hot-swappable design allows replacement during plant operation, minimizing production downtime.
Core Advantages and Technical Highlights
Intelligent Signal Conditioning: Auto-calibration compensates for temperature drift (±0.005%/°C), maintaining ±0.1% accuracy across full operating range. Automatic burnout detection provides configurable up/down-scale alerts.
Dual HART Multidrop: Each channel independently communicates with up to 15 HART devices simultaneously, enabling valve position feedback and multivariable flow meter integration without separate multiplexers.
Cyber-Secure Architecture: Configuration lockdown prevents unauthorized parameter changes. Signed firmware updates via Control Builder M meet IEC 62443 SL2 requirements.
Ultra-Compact Design: At just 23mm width, fits 48 channels in standard 19″ rack. Patented spring-loaded backplane contact ensures vibration resistance to 5g (IEC 60068-2-6).
Advanced Diagnostics: Predictive failure alerts for:
Sensor degradation (trended deviation >0.25%/month)
Ground loop detection (common-mode voltage >30V)
EMI susceptibility (noise >0.1% FS)
Typical Application Scenarios
Oil & Gas Wellhead Control: In Arctic fields, the AI02J monitors cryogenic temperature sensors (-50°C) on Christmas trees, with HART diagnostics predicting control valve stiction before freeze-ups occur.
Wastewater Treatment: Interfaces with pH/ORP sensors in aeration basins, detecting electrode fouling through HART “deviation alarm” parameter. Automatic calibration triggering reduces maintenance rounds by 40%.
Pharmaceutical Bioreactors: Measures sterile pressure transmitters with ±0.05% repeatability. HART-enabled mass flow compensation ensures precise nutrient dosing during cell culture processes.
Power Plant Emissions: Monitors CEMS (Continuous Emissions Monitoring) analyzers with validation per EPA 40 CFR Part 60. Data integrity seals prevent tampering with calibration values.
Related Model Recommendations
AO02J: Analog output counterpart with same form factor
DI02J: Digital input module for contact monitoring
PM861AK01: Controller pairing with AI02J
CI871K01: PROFIBUS interface module
TA527: Termination assembly for field wiring
SD822: SIL 3 safety-rated analog input
EXC20: I/O baseplate for hot-swap operation
ABB AI02J
Installation, Commissioning and Maintenance
Installation Preparation: Mount vertically on EXC20 baseplate using DIN rail EN 60715. Maintain 15mm clearance between modules. Use Belden 8761 shielded twisted pairs with drain wires grounded at marshalling cabinet. Torque terminals to 0.4 N·m.
Commissioning:
Auto-range detection via Control Builder M
Perform loop test with HART communicator
Set signal damping (0-60s) for noisy environments
Configure burnout direction (up/down-scale)
Maintenance Regimen:
Quarterly: Verify calibration with process calibrator
Annually: Clean backplane contacts with IPA
Replace after 15 years or 100,000 insertion cycles
Critical alarms: Red LED = channel fault; Flashing = HART communication loss
Service and Guarantee Commitment
ABB provides a 5-year warranty for the AI02J, extendable to 20 years via Life Cycle Service Agreement. Includes:
24/7 Global Support: 15-min response for critical process failures
Firmware Assurance: Free security updates until 2040
Calibration Services: ISO 17025-accredited labs
Repair Program: Flat-rate repair with 5-day turnaround
HART Migration Kits: Legacy system upgrades
Cybersecurity Audits: IEC 62443 gap analysis
