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The ABB TB820 is a high-reliability optical trunked modem designed exclusively for ABB’s AC 800M Distributed Control System (DCS) and S100 I/O platforms. Its core function is to enable long-distance, high-speed, and interference-resistant data transmission between geographically dispersed DCS components (e.g., remote I/O racks, controllers, or operator stations) via fiber-optic cables. By converting electrical signals (from ABB’s CEX bus or industrial Ethernet) to optical signals, it eliminates electromagnetic interference (EMI) and signal degradation common in copper-based communication—making it critical for large-scale industrial sites (e.g., power plants, petrochemical refineries, mining complexes) where DCS components are spread across kilometers.
The TB820 acts as a "signal translator" between electrical and optical domains, enabling reliable long-range DCS communication:
- Dual-Signal Support: Transmits both ABB’s proprietary CEX bus signals (for AC 800M controller-I/O rack communication) and standard Ethernet signals (for SCADA/HMI connectivity). For example, it can link a central AC 800M controller (in a main control room) to a remote S100 I/O rack (20km away in a power plant’s turbine hall) via single-mode fiber.
- High-Speed, Low-Latency: Maintains 100Mbps full-duplex data rate for CEX bus and 10/100Mbps for Ethernet, with latency <1ms—critical for time-sensitive DCS tasks (e.g., real-time valve control, emergency shutdown signals).
- EMI Immunity: Optical fiber transmission is immune to EMI from high-voltage power cables, motors, or welding equipment (common in industrial sites). Unlike copper cables, it avoids signal distortion or data loss caused by electrical interference.
For mission-critical applications requiring 24/7 availability, the TB820 supports redundant configurations:
- Dual Fiber Paths: Two TB820 modems can be paired to form a redundant optical link (primary/backup paths). If the primary fiber is damaged (e.g., digging accident in a refinery), the system automatically switches to the backup path within <100ms—no disruption to DCS operation.
- Link Monitoring: Continuously checks optical signal strength (received power: -30dBm to -10dBm for SM). If signal strength drops below a threshold (e.g., -28dBm, indicating fiber degradation), it triggers a local alarm and sends diagnostic data to the AC 800M controller.
To simplify maintenance of long-distance links, the TB820 provides comprehensive diagnostic features:
- LED Status Indicators:
- Green "POWER": Illuminates when the modem is powered.
- Green "CEX/Ethernet": Flashes for active data transmission; solid for link established.
- Green "OPTICAL": Flashes for normal optical signal; solid for no signal (fiber fault).
- Red "FAULT": Lights for low optical power, electrical isolation failure, or internal hardware error.
- Diagnostic Data Over Ethernet: Transmits optical link parameters (e.g., received power, signal-to-noise ratio) and fault codes (e.g., "0x04: Low Optical Power") to the AC 800M controller or SCADA system—enabling remote troubleshooting (e.g., identifying a faulty fiber splice without on-site visits).
The TB820 adapts to diverse site conditions:
- Fiber Type Flexibility: Supports both single-mode (long-distance, 20–40km) and multi-mode (short-distance, 2–5km) fiber—no need for separate modems for different fiber infrastructures.
- Outdoor Compatibility: Optional IP65 enclosure protects the modem from rain, dust, and temperature extremes (e.g., mounting on an outdoor pump station in a desert power plant).
- Hot-Swap Capability: Can be replaced without powering down the DCS (when used in redundant pairs)—minimizes downtime during maintenance.
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Long-Distance, Interference-Free Communication
Transmits data up to 40km (single-mode fiber) without EMI issues—eliminates the need for signal repeaters (common with copper cables) and reduces infrastructure costs by 40%.
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High Reliability for Critical DCS Links
Redundant fiber paths and <100ms switchover time meet the availability requirements of safety-critical systems (e.g., nuclear power plant auxiliary control, petrochemical emergency shutdown loops).
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Simplified Maintenance
Remote diagnostic monitoring and LED status indicators reduce on-site troubleshooting time—technicians can identify fiber faults (e.g., a broken cable) from the main control room, cutting maintenance costs by 30%.
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Wide Environmental Adaptability
-40°C~+70°C operating range and optional IP65 enclosure enable deployment in extreme environments (arctic pipelines, desert refineries) where standard modems fail.
- Use Case: Connects a central AC 800M controller (main control room) to a remote S100 I/O rack (15km away at a cooling tower) in a 1000MW coal-fired power plant.
- Configuration: TB820 with single-mode fiber (1310nm, 15km); redundant pair for fault tolerance.
- Value: EMI immunity avoids signal interference from high-voltage power lines; redundant links prevent cooling system control loss.
- Use Case: Transmits Ethernet data between a refinery’s central SCADA system and a remote pump station (2km away) via multi-mode fiber.
- Configuration: TB820 with multi-mode fiber (850nm, 2km); IP65 enclosure for outdoor mounting.
- Value: Optical transmission resists EMI from nearby pump motors; IP65 enclosure protects against refinery dust and rain.
- Use Case: Links an underground AC 800M controller (mining shaft) to a surface-based operator station (5km away) via single-mode fiber.
- Configuration: TB820 with single-mode fiber (1550nm, 5km); redundant paths to avoid downtime from underground fiber damage.
- Value: Long-distance transmission eliminates the need for underground repeaters; low latency ensures real-time monitoring of mining equipment.
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Fiber Compatibility Check
- Match fiber type (SM/MM) to transmission distance: Use SM for >2km, MM for ≤2km.
- Ensure fiber connectors (SC/LC, configurable) match site infrastructure—use ABB-approved connectors (e.g., SC-UPC) to avoid signal loss.
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Optical Power Calibration
- Measure received optical power after installation (target: -30dBm to -10dBm for SM, -25dBm to -10dBm for MM).
- Avoid exceeding maximum input power (-10dBm)—use an optical attenuator if needed (prevents modem damage).
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Redundancy Setup
- When configuring redundant links, use two separate fiber paths (e.g., different trenches in a refinery) to avoid simultaneous damage (e.g., from a single digging accident).
- Enable auto-switchover via AC 800M Control Builder M software—set switchover threshold to -28dBm (SM) or -23dBm (MM).
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Outdoor Installation
- Use the optional IP65 enclosure (ABB part no. 3HAC032100-001) for outdoor deployment; ensure the enclosure is mounted 1.5m above ground (avoids waterlogging).
- Seal fiber entry points with waterproof glands (ABB part no. 3HAC032101-001) to prevent moisture ingress.
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Genuine Spare Parts
Use only ABB-approved optical modules and cables—counterfeit parts may have incorrect wavelength or power ratings, causing signal failure or modem damage. Verify authenticity via ABB’s global support portal
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