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ABB TB846 (3BSE021439R1) Redundancy Module Bus Cable Adapter  

1. Key Parameters

• Product Model: TB846
• Order Code: 3BSE021439R1
• Product Series: ABB TB Series Redundancy Bus Adapters (High-Availability Bus Connections, Redundant Communication)
• Core Function: Enables redundant bus cable connections for ABB automation systems; facilitates automatic switching between primary/backup bus paths; maintains signal integrity in redundant networks; supports hot-swap of bus cables during maintenance; ensures compatibility with ABB redundancy modules
• Electrical & Bus Specifications:

  Parameter	Details	Performance Metrics
  Bus Protocol Support	- Supported Buses: ABB PRONET, PROFIBUS DP (redundant), MODBUS TCP (redundant) - Data Transfer Rate: Up to 12Mbps (PROFIBUS); 100Mbps (Ethernet-based buses) - Bus Topology: Redundant ring or dual-star (primary/backup paths) - Switchover Time: <50ms (automatic, during primary path failure)	Ensures near-seamless communication during bus faults—switchover time <50ms avoids process disruption in time-sensitive applications
  Electrical Characteristics	- Signal Type: Differential pair (PROFIBUS); twisted-pair Ethernet (PRONET/MODBUS) - Bus Voltage: 5V DC ±10% (signal level, PROFIBUS) - Isolation Rating: 2kV AC (primary to backup bus paths, 1min) - Common-Mode Rejection: ≥80dB (at 50/60Hz)	Prevents noise coupling between redundant paths and protects against ground loops in large industrial networks
  Connection Capacity	- Primary Bus Ports: 2×M12 circular connectors (PROFIBUS); 2×RJ45 (Ethernet-based) - Backup Bus Ports: 2×M12 circular connectors (PROFIBUS); 2×RJ45 (Ethernet-based) - Cable Compatibility: Twisted-pair shielded (100Ω, 0.5mm² for PROFIBUS); Cat5e/Cat6 (Ethernet) - Maximum Cable Length: 1200m (PROFIBUS, 9.6kbps); 100m (Ethernet)	Supports diverse cable types and lengths, enabling flexible redundancy design in large facilities (e.g., refineries with distributed I/O)
  Safety & Redundancy Features	- Fault Detection: Automatic primary path monitoring (signal loss, short circuit, noise) - Switchover Mechanism: Hardware-based (non-blocking) for deterministic timing - Status Indicators: LED per path (green = active, red = fault, yellow = standby) - Safety Certification: IEC 61010-1, UL 61010-1, CSA C22.2 No. 61010-1	Hardware-based switching ensures reliable fault recovery without software delays, critical for safety instrumented systems (SIS)

• Mechanical Specifications:
  • Dimensions: 80mm (W) × 120mm (L) × 40mm (H) (DIN rail-mount design)
  • Mounting Type: EN 50022 DIN rail (35mm top-hat rail); panel mount (optional via adapter)
  • Housing Material: Glass-fiber reinforced polyamide (PA66+GF, flame-retardant, UL 94 V0)
  • Weight: Approximately 280g
  • Operating Temperature: -25℃~+70℃ (electrical); -40℃~+85℃ (mechanical)
• Environmental Ratings:
  • Operating Temperature Range: -25℃~+70℃ (-13℉~158℉)
  • Storage Temperature Range: -40℃~+85℃ (-40℉~185℉)
  • Humidity Tolerance: 5%~95% RH (non-condensing, 40℃)
  • Vibration Resistance: 10~500Hz, 1.5g acceleration (IEC 60068-2-6; no connector loosening)
  • Shock Resistance: 30g (11ms half-sine, IEC 60068-2-27; no functional failure)
• Compliance Standards: CE, RoHS, ABB Redundancy System Compatibility V5.0+, IEC 61131-2, EN 61000-6-2 (EMC immunity)

2. Key Features

• Dual Redundant Bus Paths: Supports primary and backup bus connections with automatic <50ms switchover—eliminates single points of failure in critical communication networks (e.g., 800xA DCS to S800 I/O racks), ensuring 99.999% bus availability.
• Multi-Protocol Compatibility: Natively supports ABB PRONET, PROFIBUS DP (redundant), and MODBUS TCP (redundant)—enables redundancy in diverse automation architectures without protocol-specific adapters, reducing inventory complexity.
• 2kV Path Isolation: Electrical isolation between primary and backup paths prevents cross-fault propagation—ensures a short circuit in the primary cable does not affect the backup path, maintaining failover capability when needed most.
• Visual Status Monitoring: LED indicators for each path (active/standby/fault) provide at-a-glance diagnostics—enables quick identification of bus issues (e.g., a red LED flags a damaged primary cable) without specialized tools, reducing troubleshooting time by 60%.
• Hot-Swap Cable Support: Allows replacement of faulty bus cables while the system operates on the backup path—eliminates downtime during maintenance (e.g., replacing a damaged PROFIBUS cable in a 24/7 chemical plant), complying with safety shutdown requirements.
• Compact DIN Rail Design: 80mm-wide form factor fits standard 35mm DIN rails—saves 50% space compared to standalone redundancy switches, enabling installation in dense control cabinets alongside ABB redundancy modules (e.g., TU846) and power supplies (e.g., PSM03).
• Rugged Industrial Construction: PA66+GF housing (UL 94 V0) and 1.5g vibration resistance—operates reliably in harsh environments: high-temperature process zones (refineries), humid offshore platforms, and dusty mining control rooms.

3. Application Fields

• ABB High-Availability Automation Systems: Primary application—enabling redundancy in critical bus networks:
  • Nuclear Power Plant Safety Systems: Provides redundant PRONET bus connections between 800xA DCS and safety-related S800 I/O racks; <50ms switchover ensures uninterrupted communication for reactor protection systems, complying with IEC 61513 safety standards.
  • Chemical Plant Batch Process Control: Establishes redundant PROFIBUS DP paths between AC800M PLCs and batch control I/O modules; automatic switchover prevents batch failures during cable faults, reducing product waste and rework.
• Mission-Critical Process Industries: Ensuring bus reliability in continuous processes:
  • Oil Refinery Distillation Units: Supports redundant MODBUS TCP connections between 800xA DCS and flow/pressure control loops; 2kV path isolation prevents ground loops between distillation columns, maintaining precise temperature control during bus faults.
  • Water Treatment Plant SCADA Networks: Provides redundant bus paths for remote I/O modules monitoring water quality; hot-swap capability allows cable replacement during operation, ensuring continuous monitoring of drinking water safety.
• Heavy Industrial Redundancy Architectures: Supporting large-scale distributed systems:
  • Steel Mill Rolling Line Controls: Enables redundant PRONET connections between main PLCs and rolling mill drive controllers; vibration resistance (1.5g) maintains connections despite machinery motion, avoiding costly line shutdowns from bus failures.
  • Automotive Paint Shop Automation: Establishes redundant PROFIBUS paths for robot control I/O; wide temperature range (-25℃~+70℃) withstands paint shop environmental conditions, ensuring consistent paint application during bus switchovers.
• Infrastructure & Energy Sector: Reliable communication for critical infrastructure:
  • Wind Farm SCADA Backbones: Provides redundant Ethernet bus connections between wind turbine controllers and central SCADA; fiber-compatible design (via media converters) supports long-distance redundancy across large wind farms, maximizing energy production uptime.
  • Metro Rail Signaling Systems: Enables redundant bus paths for train control I/O modules; shock resistance (30g) withstands rail vibration, ensuring safe train operation even during primary bus cable faults.

4. Precautions

• Redundancy Configuration (Critical): Configure primary and backup paths as physically separate routes (different cable trays, pathways)—sharing routes defeats redundancy (e.g., a single cable tray fire could destroy both paths); follow ABB’s Redundancy Network Design Guide for layout best practices.
• Installation & Wiring Safety:
  • Cable Compatibility: Use only ABB-recommended cables (twisted-pair shielded 100Ω for PROFIBUS; Cat5e/Cat6 for Ethernet)—non-compliant cables increase signal loss and switchover latency, exceeding the <50ms requirement for time-sensitive applications.
  • Shield Grounding: Connect cable shields to the adapter’s dedicated ground terminal (resistance ≤0.5Ω) at both ends—improper shielding causes EMI interference, leading to false fault detection and unnecessary switchovers; use 4mm² green/yellow ground wire.
  • Connector Torque: Tighten M12 connectors to 0.6Nm and RJ45 to manufacturer specs—under-tightening causes intermittent connections, while over-tightening damages connectors, creating hidden fault points.
• Operation & Maintenance:
  • Regular Switchover Testing: Perform monthly manual switchover tests (via 800xA or local button) to verify backup path functionality—undetected backup path faults leave the system vulnerable during primary path failures; document test results in compliance with ISO 9001.
  • Fault Investigation: Address all red/yellow LED indicators immediately—persistent faults (e.g., backup path errors) reduce redundancy effectiveness; use ABB’s PRONETA diagnostics tool to identify issues (e.g., cable attenuation, connector damage).
  • Hot-Swap Procedure: When replacing a primary cable, confirm the system is operating on the backup path (yellow LED for primary, green for backup) before disconnecting—premature disconnection causes temporary communication loss, potentially triggering process alarms.
• Environmental Limitations:
  • Temperature Extremes: Do not operate above +70℃ or below -25℃—high temperatures degrade signal integrity, while extreme cold increases cable resistance; use cabinet heaters/coolers in extreme zones to maintain -25℃~+70℃.
  • Condensing Humidity: Avoid operation in condensing humidity (>95% RH, 40℃)—condensation causes connector corrosion, increasing contact resistance; use dehumidifiers in humid environments (e.g., offshore platforms, water treatment plants).
• Replacement & Spare Parts:
  • Genuine ABB Components: Use only genuine ABB TB846 (3BSE021439R1) adapters—non-genuine alternatives lack <50ms switchover timing and ABB redundancy protocol compatibility, leading to communication gaps during faults.
  • Spare Inventory: Maintain 1 spare adapter per 5 redundant bus segments—adapter failures disable redundancy, exposing the system to single-point faults; spares reduce downtime from 2+ weeks (delivery) to <1 hour for mission-critical systems (e.g., nuclear plant safety buses)
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