Description
Detailed parameter table
| Parameter name | Parameter value |
| Product model | DI651 |
| Manufacturer | ABB |
| Product category | High-density digital input module |
| Input channels | 32 isolated channels |
| Input type | Dry contact/voltage-free |
| Input voltage range | 24 V DC (sinking/sourcing configurable) |
| Input current | 3 mA @ 24 V DC |
| Response time | <1 ms (standard mode), <0.1 ms (fast mode) |
| Isolation | 2.5 kV AC (channel-to-backplane) |
| Operating voltage | 24 V DC ±15% |
| Power consumption | Max 4 W |
| Operating temperature | -40°C to 70°C |
| Dimensions | 100mm × 160mm × 80mm |
| Mounting type | Backplane mount (compatible with AC800M/S800 series) |
| Protection rating | IP20 |
| Certifications | CE, UL, IEC 61131-2, ATEX |
ABB DI651
Product introduction
The ABB DI651 is a high-performance digital input module designed to serve as a critical data acquisition component in large-scale industrial automation systems. As part of ABB’s S800 I/O family, ABB DI651 specializes in converting a high density of discrete electrical signals from field devices—such as limit switches, proximity sensors, and emergency stop buttons—into digital data for processing by PLCs and DCS platforms like ABB’s AC800M.
With its 32-channel design, ABB DI651 offers exceptional input density, making it ideal for applications requiring monitoring of numerous discrete points. Its flexible configuration options (sinking/sourcing) ensure compatibility with diverse sensor types, while its robust isolation and wide operating temperature range guarantee reliable performance in harsh industrial environments. Whether deployed in manufacturing plants, power generation facilities, or process industries, ABB DI651 delivers accurate and timely data acquisition, forming a foundational element of modern automation systems.
Core advantages and technical highlights
High-density channel configuration: ABB DI651 packs 32 isolated channels into a compact form factor, reducing the number of modules required in control cabinets by up to 50% compared to 16-channel alternatives. In a large automotive plant, this density allows monitoring of 32 conveyor section sensors (e.g., part presence, jam detection) using a single module, saving valuable backplane space and simplifying wiring. Each channel operates independently, preventing cross-talk and ensuring accurate signal detection even in noisy environments.
Configurable response times: The module offers selectable response times—<1 ms for standard applications and <0.1 ms for time-critical operations—providing flexibility across diverse use cases. In a high-speed packaging line, ABB DI651’s fast mode ensures that a broken seal detection sensor triggers an immediate stop signal to the PLC, preventing defective products from proceeding down the line. For less time-sensitive applications like warehouse door status monitoring, standard mode balances performance and power consumption.
Robust isolation and noise immunity: Equipped with 2.5 kV AC isolation between channels and the backplane, ABB DI651 effectively rejects electromagnetic interference (EMI) and ground loops common in industrial settings. This isolation is particularly valuable in steel mills or welding facilities, where electrical noise can disrupt signal integrity. The module’s design also includes surge protection (2 kV per IEC 61000-4-5), safeguarding against voltage transients from motor switching or lightning strikes.
Typical application scenarios
In a large-scale food and beverage production facility, ABB DI651 monitors 32 discrete points across a bottling line, including bottle position sensors, cap feeder statuses, and label applicator triggers. Its high channel density allows centralized monitoring of the entire line in a single module, simplifying troubleshooting and reducing cabinet space. The module’s fast response mode ensures that a missing bottle detection triggers an immediate halt to filling operations, preventing spills and minimizing waste.
In a power plant’s auxiliary systems, ABB DI651 tracks the status of 32 motor control center (MCC) breakers, pump interlocks, and valve position switches. Its wide operating temperature range (-40°C to 70°C) allows installation in unheated equipment rooms, while its robust isolation ensures reliable operation despite the high electrical noise from transformers and large motors. The module communicates with the plant’s DCS, providing real-time status updates to operators and enabling predictive maintenance based on equipment cycling patterns.
ABB DI651
Related model recommendations
ABB DO651: A 32-channel digital output module that complements ABB DI651 for complete discrete I/O functionality in automation systems.
ABB AI651: An analog input module that, when paired with ABB DI651, provides mixed-signal monitoring capabilities.
ABB CI858-1 3BSE018137R1: A communication module that enables ABB DI651 to integrate with Ethernet-based control networks.
ABB PPE091A101 3BHE044481R0101: A redundant power supply ensuring stable 24 V DC power to ABB DI651 in critical applications.
ABB 07CR41 1SBP260020R1001: A control relay module that can be actuated based on input signals from ABB DI651.
ABB TB857: A surge protection terminal block that enhances ABB DI651’s immunity to voltage transients in harsh environments.
Installation, commissioning and maintenance instructions
Installation preparation: Mount ABB DI651 into a compatible S800 backplane, ensuring proper alignment with the connector pins. Torque the retaining screw to 0.5 Nm to secure the module. Connect field devices using 0.5-1 mm² shielded twisted-pair cable, with each input wired to the corresponding terminal. For sinking configuration, connect the common terminal to 0 V DC; for sourcing, connect to 24 V DC. Ground all cable shields at the module end. Use a torque screwdriver set to 0.5 Nm for terminal connections. Power off the backplane during installation to prevent electrical damage.
Maintenance suggestions: Inspect ABB DI651 quarterly for loose connections, dust accumulation, and LED status indicators (power: green, channel active: yellow, fault: red). Clean ventilation slots with compressed air to prevent overheating. Verify input functionality semi-annually by activating each connected device and confirming status updates in the controller. If channels fail to detect signals, check wiring and sensor functionality before replacing the module. Use only ABB-certified replacement modules to maintain system compatibility and performance.
Service and guarantee commitment
ABB DI651 is backed by a 5-year warranty from the date of installation, covering manufacturing defects and ensuring compliance with published performance specifications. ABB’s global technical support team provides response within 4 hours for critical issues, with remote diagnostics available 24/7 to minimize downtime. On-site service is available within 72 hours in major industrial regions for complex problems requiring hands-on assistance.
The warranty includes free access to configuration software and technical documentation. Extended service contracts offer annual preventive maintenance, performance verification, and priority support, ensuring ABB DI651 maintains optimal performance throughout its 15-year design lifespan. ABB’s commitment to quality underscores confidence in the module’s reliability as a critical component in industrial automation systems.
