ABB 3BSE038415R1 AO810V2 – 8?Channel Analog Output Module for S800 I/O

The ABB AO810V2 (order code 3BSE038415R1) is an S800 I/O analog output module designed for precise current output control in 800xA / AC 800M systems. It delivers eight independently configurable 0/4–20 mA channels for driving control valves, dosing pumps, positioners, and VFD speed references.    From my experience, it’s a go-to spare for plants standardizing on S800 I/O—compact, predictable, and easy to slot into existing terminal units.

• 8 current output channels (0/4–20 mA) – Each channel can be set to 0–20 mA or 4–20 mA, which typically covers most actuator and reference signal needs on the plant floor.

• S800 I/O platform compatibility – Seamlessly integrates with AC 800M controllers via S800 I/O ModuleBus, so no awkward adapters or wiring workarounds.

• V2 hardware revision – The AO810V2 version brings refined robustness and module diagnostics compared with early builds, which seems to help in electrically noisy cabinets.

• Compact DIN-rail footprint via TU8xx terminal units – Saves cabinet space and keeps wiring tidy, especially in brownfield expansions.

• Practical diagnostics – Module status LEDs and channel supervision help technicians pinpoint loop issues faster during commissioning or turnarounds.

• Hot-swap serviceability – In many cases, you can replace the module on its terminal base with minimal system disruption, reducing mean time to repair.

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You might notice that AO810V2 fits naturally where reliable current control matters:

• Oil & Gas and Petrochemicals – Valve position control, flow regulation, and pressure control loops.

• Water & Wastewater – Dosing pump outputs, actuator positioning, and speed references for blowers.

• Power Generation – Turbine and balance-of-plant skids needing stable 4–20 mA control signals.

• Pulp & Paper / Mining – Drives, feeders, and process actuators in harsh cabinet environments.

A controls engineer at a midstream facility told us the swap from an older AO module to AO810V2 was “a straight drop?in—same TU, same wiring, and loop checks passed on the first try,” which is typically what we see in brownfield upgrades.

• Reliability in the cabinet – The V2 hardware revision appears to handle electrical noise and temperature swings better than early versions, reducing nuisance trips.

• Drop?in compatibility – If your site already runs S800 I/O, this is the safe spare to stock; no re-training or panel redesign.

• Lower lifecycle cost – Hot?swap serviceability and clear diagnostics can cut maintenance time during turnarounds.

• Broad ecosystem support – Works with common ABB communication interfaces (e.g., CI modules) in 800xA/AC 800M architectures.

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• Cabinet and mounting – Install on a compatible TU8xx terminal unit mounted to DIN?rail in a well?ventilated cabinet. Keep analog wiring separated from high?voltage and high?frequency cables.

• Wiring practices – Use twisted?pair for analog loops; maintain proper shielding and grounding per plant standards. Observe load limits for current loops specified in the AO810V2 manual.

• Power and earthing – Feed the S800 I/O segment from a clean 24 VDC supply via the terminal unit. Ensure stable cabinet grounding to minimize noise.

• Commissioning – Verify channel configuration (0–20 mA or 4–20 mA), run loop checks with a calibrator, and confirm module status LEDs are nominal.

• Routine maintenance – Periodically inspect terminal screws for tightness, clean dust from the module area, and review diagnostic/alarm logs. Firmware dependencies are handled at the system level; check 800xA release notes for compatibility when upgrading.

• Safety – De?energize loops before rewiring. If hot?swapping, follow ABB procedures and confirm the segment is in a safe state.

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• CE compliant and RoHS aligned for industrial environments.

• cULus listing available for many S800 modules (check specific build).

• Manufactured under ISO 9001 quality systems.

• Manufacturer’s warranty: typically 12 months; extended coverage options may be available.

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If you’re consolidating spares for an S800 install base, AO810V2 is a safe pick—consistent behavior across channels, straightforward commissioning, and in most cases no surprises when you drop it into an existing TU.