Product Overview
When your industrial control system demands reliable switching of high-voltage loads, the ABB DO802 delivers. This 8-channel relay output module for the S800 I/O family handles 110 V DC and 250 V AC circuits with a maximum continuous output current of 2 A per channel. Each output is individually isolated, ensuring channel-to-channel and channel-to-circuit common protection. The module includes an optical isolation barrier, output state LED, relay driver, and EMC protection components on every channel.
Technical Specifications Breakdown
- Channel Configuration: 8 normally open (NO) relay outputs, each rated for 24...110 V DC / 250 V AC (max 2 A).
- Isolation: Individually isolated channel-to-channel and to circuit common; rated insulation voltage 250 V; dielectric test voltage 2000 V AC.
- Power Consumption: Typ. 2.2 W dissipation; draws 70 mA from +5 V ModuleBus and 80 mA from +24 V ModuleBus.
- Diagnostics: Front LED status indicators for module status and channels 1-8; relay power converter supervision provides module error, module warning, and channel error signals.
- Environmental: Operating temperature 0 to +55 °C (approvals +5 to +55 °C); storage -40 to +70 °C; IP20 protection; pollution degree 2; corrosion protection ISA-S71.04 G3.
Industry Applications
The DO802 excels in applications requiring discrete on/off control of AC or DC loads such as motors, valves, solenoids, and indicators. Its individually isolated channels make it ideal for mixed-voltage panels where load isolation is critical. For example, in a water treatment plant, the module can independently control pumps and valves at different voltage levels while maintaining galvanic isolation. The relay output type also suits high-inrush current loads common in industrial machinery.
Installation & Setup Guidance
Mount the DO802 on an S800 I/O rail (S800L mechanics). Use detachable connectors for process wiring. Supported wire sizes: solid 0.05-2.5 mm² (30-12 AWG) or stranded 0.05-1.5 mm² (30-12 AWG). Recommended torque: 0.5-0.6 Nm. Strip length: 6-7.5 mm (0.24-0.30 inch). Maximum field cable length is 600 meters (600 yards). Ensure the 24 V distributed on the ModuleBus is present for relay supply voltage supervision; this feature can be enabled/disabled via parameter.
Maintenance & Reliability
Routine inspection should focus on the relay contacts and LED indicators. The module's EMC protection components and optical isolation reduce wear from electrical noise. Operate within the specified temperature range (0 to +55 °C; derate to +40 °C for vertical mounting) to maximize relay life. The supervision monitor alerts you if the relay power converter voltage disappears, enabling proactive maintenance.
Compatibility & Integration
The DO802 is part of the ABB S800 I/O system, compatible with AC 800M, AC 800F, and other ABB controllers via the ModuleBus. It supports HART and SOE (not applicable for this digital output), and redundancy is not available. For system integration, ensure your controller supports the S800 I/O series and the ModuleBus protocol.
Selection Guide & Purchasing Advice
Before ordering, verify your system's I/O requirements: channel count (8), voltage (110 V DC/250 V AC), and current (2 A max). The DO802 (article number 3BSE022364R1) is a non-intrinsically safe, non-high-integrity module. For current availability and lifecycle status, contact SpareTechPLC. We stock this module and can advise on compatible accessories.
Troubleshooting & Common Issues
- Module Error/Warning: Check the 24 V ModuleBus supply. The relay supply voltage supervision triggers a channel signal error and module warning if voltage is lost.
- Channel Failure: Verify the relay driver and optical isolation barrier. Use the channel status LEDs to identify faulty channels.
- No Output: Confirm the load voltage and current are within the 250 V / 2 A limits. Check wiring connections and torque.
Frequently Asked Questions
Q1: Can the DO802 handle both AC and DC loads?
Yes, each channel supports 24...110 V DC or 250 V AC (max 2 A).
Q2: Are the outputs individually isolated?
Yes, each channel is individually isolated from other channels and from circuit common.
Q3: What is the maximum cable length to field devices?
600 meters (600 yards).
Q4: Does the module require external 24 V for relay operation?
No, the relay supply voltage is derived from the 24 V distributed on the ModuleBus.
Q5: Is the DO802 suitable for safety-critical applications?
No, it is not high integrity or intrinsically safe. For safety-rated systems, consult ABB's safety product line.
