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ABB TB840 Modular Bus Trunk Modem

1. Product Overview

2. Core Specifications

3. Key Functions

3.1 Multi-Media Bus Trunking (Copper + Fiber)

• PROFIBUS DP over Copper: Supports short-to-medium distance communication (up to 1.2km) for fieldbus devices (e.g., ABB AI830 I/O modules, third-party sensors) via twisted-pair cables—ideal for dense, localized DCS networks (e.g., a petrochemical reactor’s nearby I/O racks).
• CEX Bus/PROFIBUS over Fiber: Extends communication to remote DCS components (up to 40km via SM fiber) — eliminates EMI interference from high-voltage cables or motors, and avoids signal degradation common in long copper links.
• Dual-Media Redundancy: Can simultaneously use copper (primary) and fiber (backup) paths—if one media fails (e.g., copper cable damage), the modem switches to the other within <50ms (faster than TB820’s 100ms).

3.2 Redundant Trunking for High Availability

• Module Redundancy: Two TB840 modules (primary/standby) share the same bus trunk—if the primary module fails (e.g., hardware error), the standby takes over instantly with no data loss.
• Path Redundancy: Configurable dual fiber/copper paths between DCS nodes (e.g., Controller A ↔ Remote I/O B via Fiber Path 1 and Copper Path 2) — prevents single-point failures from cable damage (e.g., digging accidents in refineries).

3.3 Advanced Diagnostics & Network Management

• Real-Time Status Monitoring:
  • LED Indicators: Green (POWER/Link), Yellow (Data Transmission), Red (Fault) for both copper and fiber interfaces—quickly identifies media-specific issues (e.g., "Fiber Link Down" vs. "Copper Short Circuit").
  • Diagnostic Data: Transmits bus load (0–100%), signal strength (dBm), and fault codes (e.g., "0x05: PROFIBUS Overload") to the AC 800M controller via CEX bus—enables remote network health checks.
• PROFIBUS Network Analysis: Built-in PROFIBUS DP diagnostic tools (e.g., bus cycle time measurement, node error counting) — helps identify bottlenecks (e.g., "PROFIBUS Bus Load >90%") before they cause DCS delays.

3.4 Modular Expansion & Easy Integration

• Interface Module Swap: Copper/fiber interface modules are hot-swappable—replace a faulty fiber module without powering down the DCS, reducing downtime to <5 minutes.
• Seamless DCS Integration: Configured via ABB Control Builder M software (same tool for AC 800M setup) — no third-party software required, simplifying commissioning.
• Wide Device Compatibility: Works with all ABB CEX bus modules (e.g., CI801, TU847) and PROFIBUS DP devices (e.g., Siemens S7-1200 PLCs) — avoids vendor lock-in for mixed-system sites.

4. Core Advantages (vs. TB820 & Competitors)

5. Typical Applications

5.1 Power Plant Multi-Rack DCS Network

• Use Case: Connects 3 AC 800M controllers (main control room) to 4 remote S100 I/O racks (2–20km away) in a 1500MW combined-cycle power plant.
• Configuration: TB840 with SM fiber (1550nm, 20km) for remote racks and copper (PROFIBUS DP) for nearby racks; module + path redundancy.
• Value: Dual-media links ensure no downtime if fiber/copper fails; PROFIBUS diagnostics prevent bus overload during peak power generation.

5.2 Petrochemical Reactor PROFIBUS Trunk

• Use Case: Trunks PROFIBUS DP signals between 20 AI/DO modules (reactor area) and an AC 800M controller (500m away) via copper, with fiber backup (2km alternate path).
• Configuration: TB840 with copper (PROFIBUS DP) and MM fiber (1300nm, 2km); IP65 enclosure for outdoor-mounted modules.
• Value: Copper handles local dense I/O; fiber backup resists EMI from reactor motors; IP65 protects against refinery dust/rain.

5.3 Metallurgical Mill DCS Expansion

• Use Case: Links a new AC 800M controller (hot rolling mill) to the existing DCS (main control room, 5km away) via SM fiber, with copper PROFIBUS for on-site I/O.
• Configuration: TB840 with SM fiber (1310nm, 5km) and copper (PROFIBUS DP); modular interface swap for future media upgrades.
• Value: Fiber avoids EMI from mill power cables; hot-swappable modules enable quick maintenance during mill shutdowns.

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