ABB TK212A (Order Code: 3BSC630197R1) Tool Cable  

1. Key Parameters

• Product Model: TK212A
• Order Code/Part Number: 3BSC630197R1 (unique identifier for procurement and compatibility verification)
• Core Function: Enables bidirectional data transmission (programming, configuration, diagnostics) and optional power supply between ABB automation tools and industrial control systems
• Cable Type: Shielded twisted-pair (STP) industrial tool cable (for noise immunity)
• Electrical Specifications:
  • Conductor Configuration: 4 conductors (2 pairs for data, 2 for optional power)
  • Conductor Gauge: 24 AWG (0.25mm²) stranded copper (flexible for repeated handling)
  • Insulation Material: Polyvinyl Chloride (PVC) (resistant to industrial oils and chemicals)
  • Shielding: Tinned copper braid (90% coverage) + aluminum foil (for EMI/RFI suppression)
  • Rated Voltage: 300V AC/DC (for power conductors); 100V AC/DC (for data conductors)
  • Current Rating: 1A (max continuous for power conductors)
  • Data Transmission Speed: Up to 10Mbps (compatible with ABB’s tool communication protocols)
  • Transmission Distance: 5m (standard length; custom lengths available via ABB customization)
• Mechanical Specifications:
  • Cable Outer Diameter: 6.5mm ± 0.3mm
  • Outer Jacket Material: Thermoplastic Elastomer (TPE) (flexible, oil-resistant, flame-retardant)
  • Jacket Color: Black (high visibility in industrial environments)
  • Connector Type:
    • Tool End: USB Type-B (male; compatible with ABB programming tools/laptops)
    • Control System End: ABB proprietary 8-pin D-sub (male; compatible with AC 800M/Advant OCS controller ports)
  • Bend Radius: Static: ≥15mm (6× outer diameter); Dynamic: ≥30mm (12× outer diameter)
  • Weight: Approximately 0.25kg (for 5m length)
• Environmental Ratings:
  • Operating Temperature Range: -20℃~+70℃ (-4℉~158℉)
  • Storage Temperature Range: -40℃~+85℃ (-40℉~185℉)
  • Oil Resistance: Compliant with IEC 60811-404 (resistant to mineral oils and industrial lubricants)
  • Flame Retardancy: UL94 V-0 (self-extinguishing within 10 seconds)
  • Chemical Resistance: Resistant to dilute acids, alkalis, and industrial solvents
• Compliance Standards: IEC 60228 (conductor standards), IEC 60811 (cable insulation), UL 758 (industrial cables), EN 50525 (EMC performance for industrial cables)

2. Key Features

• Dual-Function Design: Integrates 2 data pairs (for programming/configuration) and 2 power conductors (for optional tool power supply)—eliminates the need for separate data and power cables, simplifying tool setup in control cabinets.
• EMI/RFI Suppression: Tinned copper braid (90% coverage) + aluminum foil shielding blocks electromagnetic and radio frequency interference from industrial equipment (e.g., motors, inverters, transformers). Ensures error-free data transmission during on-site maintenance in noisy environments.
• Industrial-Grade Durability: TPE outer jacket resists oil, chemicals, and mechanical abrasion—withstands repeated handling, bending, and exposure to industrial debris (e.g., dust, metal shavings) common in manufacturing or mining sites.
• ABB Proprietary Connector Compatibility: The 8-pin D-sub connector at the control system end is engineered exclusively for ABB AC 800M DCS and Advant OCS controllers—ensures secure mechanical fit and reliable electrical contact, avoiding loose connections that cause data loss.
• Flexible Installation: Small outer diameter (6.5mm) and wide bend radius tolerance enable easy routing through tight spaces (e.g., between control cabinet components, around equipment) without damaging the cable.
• Flame-Retardant & Safety Compliant: UL94 V-0 flame retardancy and 300V rated insulation meet industrial safety standards, reducing fire risk in high-temperature environments (e.g., refineries, power plants).
• Plug-and-Play Operation: No additional drivers or configuration required—connects directly to ABB tools and controllers, enabling immediate use for commissioning (e.g., loading control programs) or troubleshooting (e.g., retrieving fault logs).

3. Application Fields

• AC 800M DCS Commissioning: Transmits control programs, I/O configurations, and firmware updates between ABB programming laptops and AC 800M processors (e.g., PM866K02, PM861AK02)—critical for initial system setup in power plants or chemical facilities.
• Advant OCS Legacy System Maintenance: Connects to Advant OCS controllers (e.g., MasterPiece 200/300) for retrieving diagnostic data, modifying batch recipes, or repairing control logic in older industrial facilities.
• Robot Controller Programming: Used with ABB industrial robots (e.g., IRB series) to load motion programs, calibrate sensors, and adjust robot parameters during on-site deployment in automotive or electronics manufacturing.
• Industrial Control System Troubleshooting: Facilitates real-time data exchange between ABB tools and controllers to monitor process variables, log faults, and test I/O signals—reducing downtime in manufacturing lines or water treatment plants.
• Field Service & Calibration: Enables ABB field technicians to configure or recalibrate control modules (e.g., BC810K02-eA I/O modules) or sensors in remote locations (e.g., offshore platforms, pipeline stations) via portable tools.

4. Precautions

• Compatibility Check: Use exclusively with ABB automation tools (e.g., laptops with Control Builder M software) and compatible controllers (AC 800M, Advant OCS, ABB robot controllers). Third-party tools or non-ABB systems may cause communication failures or damage connectors.
• Connector Handling: Avoid bending or twisting connectors during insertion/removal—misalignment can damage pins in the proprietary 8-pin D-sub connector, leading to permanent communication issues. Clean connector pins with a dry cloth before use to remove dust.
• Voltage/Currrent Limits: Do not exceed the 300V AC/DC rated voltage or 1A current for power conductors. Overloading the power pair can melt insulation or damage the control system’s tool port.
• Environmental Protection: Do not expose the cable to temperatures beyond -20℃~+70℃ or submerge it in water (the cable is not waterproof). In humid or corrosive environments (e.g., coastal plants), store the cable in a sealed bag when not in use.
• Avoid Mechanical Damage: Do not pull the cable by the connectors (stress can break internal conductors) or run it over by heavy equipment. Use cable ties to secure the cable away from moving parts (e.g., conveyor belts, robot arms).
• EMI Avoidance: Route the cable away from high-power cables (≥30cm spacing) or electromagnetic sources (e.g., motor drives, transformers). Even with shielding, close proximity can cause temporary data errors.
• Replacement Guidelines: Replace the cable if the outer jacket is cracked, shielding is exposed, or connectors are bent/damaged. Damaged cables may cause intermittent communication or pose electrical hazards