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The ABB DI04 is a 4-channel, 24V DC digital input module belonging to the ABB Freelance DCS (Distributed Control System) and AC 800M PLC (Automation Controller 800M) families. It is designed to interface with field devices like push buttons, switches, proximity sensors, and other dry contacts.
| Parameter | Specification |
|---|---|
| Product Family | Freelance / AC 800M (S800 I/O) |
| Module Type | Digital Input (DI) |
| Number of Channels | 4 |
| Input Type | Sink or Source (see wiring diagram) |
| Nominal Input Voltage | 24 V DC (-25% / +30%) |
| Rated Voltage Range | 18 V DC to 31.2 V DC |
| "1" Signal Level | 15 V DC to 31.2 V DC (ON state) |
| "0" Signal Level | -3 V DC to 5 V DC (OFF state) |
| Input Delay Time | Typically 3 ms (for filtering/debouncing) |
| Input Current | Typically 3.5 mA per channel at 24 V DC |
| Isolation | • 500 V AC between field side and system side • 500 V AC between channels (in groups of 2) |
| Connection | Removable screw terminal block (front or top connectable) |
| Status Indicators | • Green LED (CHx) per channel: Indicates ON (24V present) state. • Red LED (MOD): Module fault indicator. |
| Internal Power Supply | Powered by the S800 I/O bus (from the fieldbus adapter) |
| Power Consumption | Typically 10 mA from the S800 I/O bus |
| Order Number / Article Code | ****3BSE008514R1` (Common variant, always verify for your specific hardware) |
The DI04 module converts the state (ON/OFF) of a field device into a digital signal that the AC 800M or Freelance controller can process. It is used to monitor the status of:
Pushbuttons and selector switches
Limit switches and proximity sensors (PNP)
Relay and contactor contacts
Any other device that provides a dry contact or a 24V DC signal.
A key feature of the DI04 is its flexibility to be wired in either a sinking or sourcing configuration, depending on the field device. The internal channel groups are isolated in pairs (Channels 1-2 and 3-4).
Sinking (more common): The field device provides the positive voltage (24V DC), and the DI04 input is the common ground (sink). When the device is active, current sinks into the module.
Sourcing: The DI04 module provides the positive voltage (via an external power supply connected to the terminal), and the field device connects it to ground (source). When the device is active, current sources from the module.
The terminal assignment and internal circuit diagram, typically found in the manual, clarify this. The standard wiring often uses the sinking mode.
Simplified Sinking Wiring Example:
Terminal A1/A2: 0V (Common for Ch 1-2)
Terminal A3: Input for Channel 1
Connect the positive lead from your field switch/sensor to +24V DC.
Connect the negative lead from your field device to Terminal A3.
When the switch closes, 24V is applied to the input, and the green LED for that channel lights up.
External Power Supply: The module itself is powered by the S800 backplane. However, the field circuit (24V DC) must be provided by an external, isolated power supply. This is a common point of confusion.
Fusing: It is good engineering practice to protect each input channel or group of channels with an external fuse (e.g., 2A) on the 24V DC supply line.
Compatibility: The DI04 module must be mounted in an S800 I/O station (e.g., a FI810F, FI820F, or FI830F base unit) and requires a corresponding Fieldbus Adapter (e.g., CI851, CI854, etc.) to communicate with the controller.
Configuration: The module is configured using ABB's engineering tools like Control Builder Plus or Freelance Engineering. The configuration is straightforward, typically just defining the channel's process signal name and alarm settings.
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