ABB 1KHL016009R0001 G4AK Thermocouple Module – 4-Channel, K-Type, S800 Remote I/O

Technical Specifications

Main Features and Advantages

4-channel K-type TC in a single S800 slot.​ The ABB 1KHL016009R0001 G4AK​ hits a sweet spot for small-to-medium temp-zone counts. Where an 8-channel AI830 would leave four channels dead-weighted, the G4AK gives you exactly four K-type inputs in one single-width S800 card — useful on skid builds, machine-level I/O cabinets, and retrofits where rack real estate is tight. Each channel is galvanically isolated from its neighbors and from the backplane, which matters on process trains where TC sensors sit at different potentials (e.g., grounded-junction TCs on different equipment grounds).Noise immunity for industrial process floors.​ K-type TC signals are low-level mV riding on long sensor leads that often run through switchgear bays, VFD cable trays, and motor power corridors. The ABB 1KHL016009R0001 G4AK​ applies S800’s galvanic-isolation architecture plus input filtering per channel, giving rejection of common-mode noise that would otherwise drift a temp reading by several degrees — and in a reactor jacket or sterilizer, a few degrees is the difference between spec and batch reject.Hot-swap capability.​ Like the broader S800 I/O family, the ABB 1KHL016009R0001 G4AK​ supports hot replacement (when the controller/PM8xx/AC800M is configured for it and the rack is powered). A maintenance tech can swap a failed TC card during a running campaign without powering the entire I/O rack, provided the S800 adapter and controller firmware support live swap. For continuous-process plants where an I/O rack shutdown means a line stop, this is a major availability advantage.Integration with 800xA, AC800M, Freelance.​ The ABB 1KHL016009R0001 G4AK​ drops into the same S800 rack that hosts your DI810/DO810/AI810/AO810, speaking ModuleBus to the controller and appearing in Control Builder/800xA hardware tree as a standard S800 node. No custom function blocks — the TC linearization, CJ compensation, and engineering-unit scaling are handled in the module/firmware layer, so the control engineer sees °C values on the wire.Industrial build quality.​ Conformal coating, 24 V DC backplane feed, and the S800 mechanical latch system mean the ABB 1KHL016009R0001 G4AK​ survives the thermal cycling, vibration, and EMI of process cabinets — from brewery CIP skids to pharma bioreactor jackets to plastics extruder zones. For plant stores managing S800 spares, the G4AK is a low-cost, high-turn item worth keeping 1–2 pieces on the shelf, especially in facilities with multiple K-type TC loops scattered across skids.

Application Field

The ABB 1KHL016009R0001 G4AK​ sits on process and machine skids where K-type thermocouples are the dominant temp sensor — which covers a large swath of industrial measurement:

• Batch process & pharma/biotech: reactor jacket temp, CIP return temp, sterile-hold loops — typically 3–5 TC points per skid, perfectly matched to a single ABB 1KHL016009R0001 G4AK​ instead of oversizing to an 8-ch card.
• Food & beverage: pasteurizer zones, brew kettle mantles, filler-head temp probes — K-type is cheap, robust, and the 4-ch G4AK fits small-panel budgets.
• Plastics & extrusion: barrel zone temps (often K-type along the screw), die-head temp — multiple small machines fed from one S800 rack with a mix of G4AK and AO810 for zone control.
• Machine builders / OEM skids: packaging lines, fillers, cappers where the OEM standardizes on ABB AC800M + S800 I/O and needs a predictable 4-ch TC card across every skid bill-of-materials.
• Energy & utilities auxiliaries: lube-oil temp on turbine skids, bearing temp on pump sets, jacket-water temp on diesel gensets — K-type TC is the default sensor, and the ABB 1KHL016009R0001 G4AK​ lands cleanly in the S800 rack next to the DI/DO that handles the trip/alarm logic.
• Retrofit of legacy ABB I/O: plants migrating from older Advant S400/S600 I/O toward S800 often find the G4AK a drop-in-competent replacement for legacy 4-ch TC cards, preserving sensor wiring (K-type leads + CJ reference) while moving to 800xA/Freelance.

Because the ABB 1KHL016009R0001 G4AK​ is an S800 infrastructure spare, its “application” is really about how many K-type loops per cabinet. Any plant running ABB 800xA, AC800M, or Freelance with S800 racks should inventory G4AK for the skids and small-bay cabinets where 4 TC channels is the right granularity. During DCS cabinet refurbishments (typically 12–18 year mark for S800), the TC-input cards are among the more static-sensitive spares in the rack — a reason to keep tested ABB 1KHL016009R0001 G4AK​ units on the critical-shelf alongside the DI810/DO810 workhorses.

Related Products

• ABB AI830 / AI830A​ – 8-channel thermocouple/mV input module (S800); higher density sibling when 4 ch is insufficient and you can fill 8 TC loops.
• ABB AI835​ – 8-channel TC/mV with sensor-break detection enhancements; alternative to G4AK when more diagnostics are needed.
• ABB AI810​ – 8-channel voltage analog input (0–10 V / ±10 V), often paired with G4AK in the same S800 rack for mixed temp + analog skids.
• ABB AO810​ – 8-channel analog output, commonly in the same rack as ABB 1KHL016009R0001 G4AK​ for Temp-PID → valve/SSR control loops.
• ABB DI810 / DO810​ – 16-ch digital I/O modules, the bread-and-butter companions to G4AK on S800 racks (alarms, contact closures, SSR drive).
• ABB PM856 / PM866 / PM891​ – AC800M controller CPUs that host the S800 rack containing the ABB 1KHL016009R0001 G4AK; the two are specified together in 800xA / Freelance BOMs.
• ABB TU810 / TU812 / TU813​ – S800 terminal units (front-side TB) that terminate the K-type TC leads for the G4AK; must match the S800 rack version (compact vs. standard) when ordering spares.