AFC094AE02 3BHE038576R0102 | 16-point AO card with ±0.05% accuracy for valve and drive control

Application Scenarios:

At a Scandinavian district heating plant modernizing its combustion control system, engineers faced a dual challenge: achieving sub-0.1% fuel-to-air ratio stability while integrating smart HART-enabled positioners across 96 control valves. Legacy 8-channel AO cards lacked both density and HART capability, requiring external multiplexers. The solution was the ABB AFC094AE02—six modules replaced twelve older cards, halving cabinet space. More importantly, each AFC094AE02 simultaneously output 4–20 mA signals and communicated HART commands to configure, calibrate, and diagnose positioners—all over the same two wires. During commissioning, a sticky valve was identified via real-time HART feedback before it caused thermal imbalance, showcasing how the AFC094AE02 transforms analog outputs into intelligent control endpoints.

Parameter:

Main Parameters Value/Description

Product Model **AFC094AE02 **(3BHE038576R0102)

Manufacturer ABB

Product Category Analog Output (AO) Module / S900 I/O Module

Number of Channels 16 (individually configurable)

Output Signal Range 4–20 mA (standard), 0–20 mA (configurable)

Load Capability Up to 750 Ω per channel at 24 VDC

Accuracy ±0.05% of full scale (at 25°C)

HART Support Yes—supports HART Revision 5/6/7; superimposes digital signal on 4–20 mA loop

Electrical Isolation 500 VAC between field and backplane; channel-to-channel isolation via design

Response Time <1 ms (typical)

Diagnostic Features Per-channel open-circuit detection, overrange/underrange alerts, HART device status

Power Consumption Approx. 4.2 W (from I/O backplane)

Operating Temperature 0°C to +60°C

Certifications CE, UL, CSA, IEC 61508 SIL2 (for use in safety-related systems)

Technical Principles and Innovative Values:

• True HART Integration: Unlike basic AO modules that merely pass HART signals, the AFC094AE02 actively participates in HART communication—enabling online device configuration, calibration verification, and predictive diagnostics directly from System 800xA.

• High Channel Density with Precision: 16 high-accuracy channels in a single module reduce hardware count, wiring complexity, and cost—without compromising performance in demanding loops like boiler drum level or turbine speed control.

• SIL2-Certified Reliability: Designed and tested per IEC 61508. the AFC094AE02 can be deployed in safety instrumented functions (SIFs) up to SIL2. ensuring fail-safe behavior under fault conditions.

• Advanced Diagnostics: Detects open circuits, short circuits, and signal deviations in real time—alerting operators before minor issues escalate into process upsets.

• Hot-Swap Ready: Supports live replacement when installed on compatible S900 baseplates, minimizing downtime during maintenance.

Application Cases and Industry Value:

In a U.S. biopharmaceutical facility producing monoclonal antibodies, precise pH and dissolved oxygen control in bioreactors is essential for cell viability. The plant upgraded its control system using ABB AFC094AE02 modules to drive gas blending valves and acid/base dosing pumps. The ±0.05% accuracy ensured nutrient delivery within ±0.5% of setpoint—critical for batch consistency. During a routine HART poll, one AFC094AE02 flagged a positioner with degraded internal damping; the valve was replaced during scheduled cleaning, avoiding a potential batch loss valued at $2.3 million. Over 18 months, the facility achieved 100% batch success rate, attributing part of this reliability to the precision and intelligence of the AFC094AE02.

Related Product Combination Solutions:

• ABB TB910: S900 I/O baseplate—provides power, communication, and hot-swap support for AFC094AE02.

• ABB PM866: Redundant AC 800M CPU—processes control logic and sends output values to AFC094AE02 with deterministic timing.

• ABB AFC093AE02: 8-channel analog input counterpart—often paired with AFC094AE02 for closed-loop control strategies.

• ABB IMRIO02: Redundant I/O interface—ensures uninterrupted output signal delivery during network or controller switchover.

• ABB AO810: S800 analog output module—used in non-HART or cost-sensitive applications; AFC094AE02 is its high-end S900 evolution.

• ABB CI858: Redundant Profibus DP/V1 module—for connecting AFC094AE02-equipped remote I/O stations in large plants.

• **ABB 3BHE038577R0102 **(AFC094BE02)—a variant with extended temperature range for harsh environments.

• ABB System 800xA Asset Optimizer: Software suite that leverages HART data from AFC094AE02 for predictive maintenance and performance trending.

Installation, Maintenance, and Full-Cycle Support:

Installing the ABB AFC094AE02 requires mounting it on an S900 baseplate (e.g., TB910) and connecting field devices to the removable spring-clamp terminal block. Each channel supports independent wiring for maximum flexibility. In Control Builder M, engineers assign engineering units, enable HART, and set diagnostic thresholds—no external configuration tools needed.

Maintenance is proactive: System 800xA continuously monitors HART device health and AO signal integrity. If a loop fails open, the module logs the event and triggers an alarm—often before the process is affected. Calibration intervals are extended thanks to factory-trimmed accuracy and long-term stability.

We supply only genuine AFC094AE02 3BHE038576R0102 units—each validated for output accuracy, HART communication, and diagnostic functionality on live S900 test rigs. Every module includes original labeling, traceable serial numbers, and a 12-month warranty. Our team provides HART integration guides, loop testing procedures, and SIL2 compliance documentation. Contact us for a customized solution—because in precision control, every milliamp matters.

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