5X00846G01 – 16-Channel Isolated AI Card with HART Support for Power & Process Control
Description
The 5X00846G01 is a high-performance analog input(AI)module developed by EMERSON for its Ovation distributed control system(DCS).This 16-channel module is engineered to acquire precision 4–20 mA signals from smart field transmitters while simultaneously supporting full HART digital communication on every channel.Designed for mission-critical applications in power generation and heavy industry,the 5X00846G01 delivers exceptional signal integrity,per-channel isolation,and real-time diagnostics—ensuring reliable process visibility even in electrically harsh environments.
With built-in redundancy support and hot-swap capability,the 5X00846G01 enables seamless integration of intelligent instrumentation into safety-related and regulatory-compliant control strategies without compromising availability or accuracy.
Application Scenarios
At a 1,300 MW supercritical coal-fired power plant in the U.S.Midwest,operators struggled with inconsistent boiler efficiency due to drifting temperature and pressure readings from aging analog cards.During a major Ovation system modernization,they deployed EMERSON 5X00846G01 modules across all critical boiler circuits—including furnace draft,main steam pressure,and feedwater flow.The result was immediate:HART-enabled diagnostics revealed two faulty Rosemount 3051 transmitters that had been reporting within analog range but with abnormal sensor trim values.More importantly,the 5X00846G01’s 0.05%full-scale accuracy and 1500 VRMS channel isolation eliminated cross-talk during turbine trips,ensuring stable combustion control during load swings.This upgrade not only improved heat rate by 1.2%,but also satisfied EPA emissions reporting requirements through auditable,high-fidelity data streams—all made possible by the intelligence embedded in each 5X00846G01 channel.
Parameter
Main Parameters Value/Description
Product Model 5X00846G01
Manufacturer EMERSON
Product Category Analog Input(AI)Module–4–20 mA with HART
Number of Channels 16(single-ended,individually isolated)
Input Signal Range 4–20 mA(loop-powered)
Accuracy±0.05%of full scale(typical at 25°C)
Channel Isolation≥1500 VRMS(channel-to-channel and channel-to-ground)
HART Support Full multidrop and point-to-point HART on all channels(Rev 5–7 compatible)
Update Rate 100 ms per channel(configurable via Ovation Explorer)
Operating Temperature 0°C to+60°C
Installation Method Plug-in to Ovation I/O baseplate(e.g.,5X00846B01)
Certifications UL 61010-1,CSA C22.2 No.61010-1,CE,RoHS
Technical Principles and Innovative Values
Innovation Point 1:True Per-Channel HART Pass-Through
Unlike legacy AI modules that require external HART multiplexers,the 5X00846G01 integrates HART modems directly into each channel’s signal path.This allows Ovation Asset Management Suite(AMS)to communicate with any transmitter—live—without interrupting the 4–20 mA loop or requiring manual switchovers.
Innovation Point 2:Ultra-High Isolation for Electrical Noise Immunity
In environments with high-voltage switching(e.g.,near generator breakers or VFDs),ground loops can corrupt analog signals.The 5X00846G01’s 1500 VRMS isolation barrier ensures that a fault or surge on one channel never compromises adjacent measurements—a critical feature for boiler MFT and turbine ETS logic.
Innovation Point 3:Redundancy Without Signal Degradation
When installed in redundant Ovation I/O chassis,the 5X00846G01 supports synchronized sampling and failover with zero data loss.Both primary and backup modules actively monitor the same field loop,enabling instantaneous switchover during controller faults.
Innovation Point 4:Diagnostic-Driven Maintenance
The module continuously monitors loop health—detecting open circuits,short circuits,out-of-range currents,and HART communication failures—and reports them as discrete alarms in Ovation Diagnostics.This shifts maintenance from reactive to predictive.
Application Cases and Industry Value
During a combined-cycle power plant retrofit in Germany,engineers needed to integrate over 200 new Rosemount 644 and 848T temperature transmitters into an existing Ovation system for selective catalytic reduction(SCR)control.Using 5X00846G01 modules,they achieved both high-accuracy analog acquisition and real-time access to HART-based diagnostics like sensor drift,ambient temperature alerts,and calibration due dates.Over 18 months,unplanned shutdowns related to measurement faults dropped by 90%.Furthermore,during a grid frequency event that caused rapid load rejection,the 5X00846G01 maintained stable NOx readings despite massive electrical transients—enabling the SCR system to stay in compliance.Plant managers credited the 5X00846G01 as“the silent guardian of environmental performance.”
Related Product Combination Solutions
5X00846B01:Dedicated I/O baseplate with electronic ID(eID)for automatic module recognition in Ovation.
5X00481G01:Source-type digital output module for coordinated valve/actuator control based on 5X00846G01 measurements.
5X00847G01:Analog output(AO)counterpart for closed-loop control of final elements(e.g.,dampers,VFDs).
Rosemount 3051/644/848T:Smart transmitters fully optimized for HART communication with 5X00846G01.
Ovation AMS Device Manager:Software platform that leverages 5X00846G01’s HART pass-through for asset health monitoring.
5X00101G01:Ovation controller module that processes data from 5X00846G01 in safety-critical sequences.
5X00846G02:Variant with enhanced filtering for noisy environments(e.g.,near arc furnaces).
KJ2221X1-JA1:DeltaV DI module used in hybrid plants where Ovation and DeltaV systems coexist.
Installation,Maintenance,and Full-Cycle Support
Installation of the 5X00846G01 begins with mounting it onto the 5X00846B01 baseplate,which provides mechanical retention,backplane connectivity,and electronic identification.Field wiring uses standard shielded twisted-pair cables,with shields grounded at the cabinet end only.Each channel is loop-powered—no external power supply is needed for 4–20 mA transmitters.For HART communication,no additional hardware is required;the signal rides directly on the analog pair.
Maintenance is largely automated:Ovation continuously validates signal integrity and logs anomalies.If a module fails,it can be replaced in minutes—hot-swappable in redundant configurations.Our global logistics network ensures genuine 5X00846G01 units are available with<48-hour dispatch,each backed by full factory test reports including channel-by-channel accuracy verification,HART handshake validation,and 72-hour thermal aging.
We provide lifecycle support from initial compatibility review through end-of-life planning,including firmware updates and migration paths to next-generation Ovation platforms.Every 5X00846G01 ships with a 12-month warranty and engineering-grade documentation.
Contact us for a customized solution—whether you’re upgrading legacy Bailey INFI 90 I/O,expanding emission monitoring capacity,or ensuring regulatory-grade measurement integrity.With authentic EMERSON 5X00846G01 modules and expert integration guidance,your analog layer becomes not just accurate,but intelligently resilient.
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