Product Short Description
Product Introduction
The ABB 3BSE008572R1, designated as TU838, is a high-performance Extended Module Termination Unit (MTU) specifically engineered for the ABB S800 I/O distributed control system (DCS) and 800xA automation platforms. As a critical interface component, it serves as the vital connection hub between field instrumentation (sensors, actuators, transducers) and S800 I/O modules, ensuring secure, reliable, and protected signal routing. Its passive design integrates signal termination, fuse-protected power distribution, and mechanical keying, all within a compact form factor.
Description
Technical Specifications
| Parameter | Value |
|---|---|
| Product Type | Extended Module Termination Unit (MTU) for S800 I/O |
| Order Part No. | 3BSE008572R1 |
| Model Designation | TU838 |
| Rated Maximum Voltage | 50 V DC |
| Maximum Current per Channel | 3 A |
| Signal Terminals | 16 universal signal terminals for field wiring |
| Fused Power Outlets | 2×4 fused transducer power terminals (2 channels per fuse) |
| Return Terminals | 2×4 return terminals for signal loop completion |
| Isolated Power Terminals | 2×2 L+ (Positive) and 2×2 L- (Negative) for isolated group power supply |
| Mounting Style | Horizontal mounting on 35 mm standard DIN rail |
| Mechanical Keying | 2 mechanical keys with 6 positions each (36 unique configurations) |
| Operating Temperature Range | 0 °C to +55 °C |
| Storage Temperature Range | -40 °C to +70 °C |
| Relative Humidity | 5% – 95% (non-condensing) |
| Protection Class | IP20 (prevents finger contact with live parts) |
| Dimensions | 126 mm (Length) × 64 mm (Width) × 110 mm (Height) |
| Net Weight | 0.26 kg |
| Connection Torque | 0.5 – 0.6 Nm (terminal block) |
| Certifications | CE, UL, ATEX Zone 2, ABS (Marine), BV (Marine), DNV-GL (Marine) |
| RoHS Compliance | Compliant |
| System Compatibility | ABB S800 I/O, AC 800M Controllers, 800xA DCS, Advant OCS |
Functional Features
Seamless Signal & Power Distribution
- 16-Channel Signal Termination: Provides 16 universal signal terminals for direct connection to field devices, supporting analog (4-20 mA, mV, RTD) and digital signals.
- Fuse-Protected Transducer Power: Equipped with 2×4 fused power outlets to supply excitation voltage to transducers, with individual fuses isolating faults to prevent system-wide disruptions.
- Dual Isolated Power Groups: Features 2×2 L+/L- terminals for isolated power distribution, minimizing ground loops and electromagnetic interference (EMI) in high-noise environments.
- ModuleBus Integration: Distributes the ModuleBus signal to connected I/O modules and daisy-chains to subsequent MTUs, ensuring consistent communication across the I/O system.
- Loop Completion: Integrated 2×4 return terminals simplify wiring for closed-loop signal circuits (e.g., 4-20 mA loops), reducing external wiring complexity.
Mechanical Safety & Error Prevention
- Precision Mechanical Keying: Dual mechanical keys ensure only compatible S800 I/O modules (e.g., AI810, DI810, DO814) can be installed, eliminating incorrect module insertion and potential damage.
- DIN Rail Latching Mechanism: Securely latches to 35 mm DIN rails with a locking device, ensuring stable installation and facilitating grounding for enhanced safety.
- Bi-Directional Mounting: Supports left/right mounting on DIN rails, optimizing cabinet layout flexibility and simplifying expansion.
Simplified Installation & Maintenance
- 3-Wire Connection Compatibility: Enables direct, efficient wiring of field devices using 3-wire connections, reducing installation time and material costs.
- Field-Proximity Placement: Designed for installation close to sensors/actuators, minimizing long-distance cabling and signal loss.
- Hot-Swap Ready: Works in conjunction with S800 I/O systems to support safe module replacement without full system shutdown, reducing downtime.
- Clear Labeling & Termination: Clearly labeled terminals and standardized connection points simplify wiring, testing, and troubleshooting.
Industrial-Grade Reliability
- High-Isolation Design: Ensures galvanic isolation between power and signal circuits, protecting sensitive control electronics from voltage transients and noise.
- Corrosion & Environmental Resistance: Built to withstand harsh industrial conditions, including high humidity, temperature fluctuations, and corrosive atmospheres (G3 per ISA-71.04).
- EMC Performance: Complies with strict EMC standards, ensuring stable operation in electrically noisy environments (e.g., power plants, manufacturing floors).
- Long-Term Durability: Constructed with high-quality materials to meet 24/7 continuous operation requirements, ensuring long service life and low maintenance costs.
Application Scenarios
Process Industries (Oil & Gas, Chemicals)
- Oil & Gas Platforms: Connects pressure transmitters, flow meters, and level sensors in offshore rigs and refineries, supporting ATEX Zone 2 compliance for hazardous areas.
- Chemical Plants: Terminates signals from corrosive-resistant sensors in continuous processing lines, ensuring reliable data transmission for safety-critical control loops.
- Pipeline Monitoring: Provides secure signal termination for SCADA systems monitoring long-distance gas/oil pipelines, with marine certifications supporting subsea installations.
Power Generation & Distribution
- Thermal/Hydro/Wind Power Plants: Connects temperature, vibration, and flow sensors in boiler/turbine control systems, ensuring high-reliability data acquisition for 800xA DCS.
- Electrical Substations: Terminates signals from protection relays, meters, and switchgear, supporting substation automation with IP20 and marine-grade corrosion resistance.
- HVDC & Grid Infrastructure: Facilitates signal routing for power conversion systems, ensuring precise monitoring and control of high-voltage transmission equipment.
Manufacturing & Automotive
- Automotive Production Lines: Connects sensors for robotic arms, conveyors, and quality control systems, supporting high-speed, high-reliability automation.
- Food & Beverage Processing: Terminates signals from hygienic-grade sensors in cleanroom environments, ensuring compliance with food safety standards.
- Pharmaceutical Manufacturing: Provides stable signal connections for batch processing and environmental monitoring systems, supporting GMP requirements.
Water & Wastewater Treatment
- Water/Wastewater Plants: Connects level, pH, and flow sensors in pumping stations and filtration systems, ensuring reliable control of water treatment processes.
- Desalination Plants: Terminates signals from high-pressure pumps and membrane systems, with corrosion-resistant design supporting harsh saline environments.
Marine & Offshore
- Shipboard Automation: Supports navigation, propulsion, and auxiliary machinery control systems, with ABS/BV/DNV-GL marine certifications ensuring compliance with maritime regulations.
- Offshore Wind Farms: Connects sensors in wind turbine generators, with IP20 and corrosion-resistant design protecting against saltwater exposure.
Metallurgy & Mining
- Steel Mills: Terminates signals from rolling mills, furnaces, and material handling systems, with high vibration resistance ensuring stable operation in harsh conditions.
- Mining Operations: Provides secure signal connections for conveyor systems, crushers, and ventilation control, supporting remote monitoring in underground mines.
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