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The ABB TK801V003 (order code: 3BSC950089R1) is a specialized industrial module bus extension cable engineered for reliable long-distance connectivity between ABB automation modules and system backplanes—specifically optimized for ABB S800 I/O systems, 800xA DCS, and AC800M PLC architectures. It functions as a "bus extension link," enabling flexible placement of I/O modules (e.g., in remote cabinets or distributed process skids) while maintaining high-speed data transmission, signal integrity, and electrical isolation. Designed with rugged shielding, industrial-grade connectors, and compliance with ABB bus protocols, it is a critical component in large-scale process plants, manufacturing facilities, and infrastructure projects where module placement flexibility and uninterrupted bus communication directly impact system design and operational efficiency. Below is its detailed specification:
- Product Model: TK801V003
- Order Code: 3BSC950089R1
- Product Series: ABB TK Series Module Bus Extension Cables (S800 I/O Bus Connectivity, Distributed Automation Link)
- Core Function: Extends bus connectivity between ABB automation modules and backplanes; maintains high-speed data transmission over long distances; provides electromagnetic interference (EMI) shielding; ensures compatibility with ABB S800 I/O modules and bus protocols; supports distributed module placement
- Electrical & Bus Specifications:
- Mechanical Specifications:
- Cable Length: 3 meters (standard; custom lengths available via ABB)
- Cable Jacket Material: Polyvinyl chloride (PVC) or polyurethane (PU, optional for oil resistance); flame-retardant (UL 94 V0)
- Cable Diameter: 12mm (PVC jacket); 13mm (PU jacket)
- Weight: Approximately 0.8kg (3m length, PVC jacket)
- Bending Radius: 10× cable diameter (static); 15× cable diameter (dynamic)
- Environmental Ratings:
- Operating Temperature Range: -25℃~+70℃ (-13℉~158℉) (PVC jacket); -40℃~+80℃ (PU jacket)
- Storage Temperature Range: -40℃~+85℃ (-40℉~185℉)
- Humidity Tolerance: 5%~95% RH (non-condensing, 40℃)
- Chemical Resistance: Resistant to mineral oil, grease, and mild industrial detergents (IEC 60068-2-54)
- Vibration Resistance: 10~500Hz, 1g acceleration (no conductor breakage or shield damage)
- High-Speed Long-Distance Transmission: Supports 100Mbps (PRONET) and 12Mbps (PROFIBUS) data rates over 3 meters (extendable to custom lengths)—enables distributed placement of S800 I/O modules (e.g., in remote process skids 10+ meters from main racks), reducing wiring complexity and cabinet size.
- Double-Layer EMI Shielding: Aluminum foil + copper braid shielding (90% coverage) provides ≥80dB EMI attenuation—prevents interference from nearby motor drives (e.g., ACS800), transformers, or power lines, ensuring error-free bus communication in high-noise industrial environments.
- Gold-Plated Proprietary Connectors: Low-resistance gold-plated contacts (500+ mating cycles) ensure reliable connectivity and corrosion resistance—ideal for applications requiring frequent module reconfiguration (e.g., manufacturing line upgrades) or operation in humid environments (e.g., water treatment plants).
- Dual-Jacket Options: Standard PVC jacket (-25℃~+70℃) for general industrial use; optional PU jacket (-40℃~+80℃, oil-resistant) for harsh conditions—enables deployment in cold storage (food processing), offshore oil platforms, or chemical plants with oil exposure.
- Integrated Power/Signal Lines: 8 twisted pairs (4 data + 4 power/signaling) eliminate the need for separate power cables—simplifies installation (fewer cables to route) and reduces the risk of wiring errors (e.g., mismatched power/signals).
- ABB S800 Compatibility: Designed for seamless integration with ABB S800 I/O modules (e.g., AI893, DI825), 800xA DCS, and AC800M PLCs—requires no adapters or protocol converters, ensuring plug-and-play functionality and reducing commissioning time by 30%.
- Flame-Retardant & Rugged Design: UL 94 V0 flame-retardant jacket and 1g vibration resistance—complies with industrial safety standards (e.g., IEC 60332-1) and withstands mechanical stress from cable routing or equipment vibration.
- ABB S800 I/O System Distributed Placement: Primary application—extending bus connectivity for remote modules:
- Chemical Plant Remote Process Skids: Connects S800 AI modules (4~20mA pressure sensors) in a remote reactor skid to the main 800xA DCS rack; 3m length enables flexible skid placement, while EMI shielding prevents interference from nearby agitator motors.
- AC800M PLC Factory Floor Expansion: Extends bus connectivity for S800 DO modules (24V DC valve controls) in a secondary cabinet on the factory floor; gold-plated connectors ensure reliable communication despite frequent module access during maintenance.
- High-Noise Industrial Environments: Maintaining signal integrity near heavy machinery:
- Steel Mill Control Systems: Links S800 DI modules (conveyor safety interlocks) to the main PLC rack; double-layer shielding blocks EMI from rolling mill motors, avoiding false safety triggers that disrupt production.
- Automotive Assembly Line Robotics: Extends bus for S800 AI modules (robot joint temperature sensors) to a remote cabinet; 100Mbps PRONET transmission ensures real-time temperature monitoring, preventing robot overheating.
- Harsh & Specialized Environments: Withstanding extreme conditions:
- Offshore Oil Platform Instrumentation: Uses PU-jacketed cables to connect S800 I/O modules (oil pressure sensors) to the central DCS; oil resistance and -40℃~+80℃ temperature range withstand marine humidity and cold offshore temperatures.
- Food Processing Cold Storage: Extends bus for S800 DI modules (freezer door sensors) to a remote cabinet; PVC jacket (-25℃~+70℃) operates reliably in sub-zero cold storage, while flame-retardant design complies with food safety standards (FDA 21 CFR Part 11).
- Infrastructure & Energy Sector: Supporting critical remote monitoring:
- Water Treatment Plant Pump Stations: Connects S800 AI modules (flow meters) in a remote pump station to the SCADA system; integrated power lines eliminate separate power wiring, simplifying installation in outdoor enclosures.
- Solar Farm Inverter Controls: Extends bus for S800 DO modules (inverter contactors) to a central control rack; EMI shielding prevents interference from solar inverter power electronics, ensuring consistent energy production monitoring.
- Cable Length & Data Rate Matching (Critical): Do not exceed 30 meters for 100Mbps PRONET or 100 meters for 12Mbps PROFIBUS—longer lengths increase latency and signal loss, causing bus errors; use ABB’s signal attenuation calculator for custom length validation.
- Installation & Wiring Safety:
- Shield Grounding: Connect the drain wire to a dedicated ground terminal (resistance ≤0.5Ω) at both ends of the cable—single-ended grounding reduces EMI protection, leading to signal corruption; use 22AWG green/yellow ground wire for consistency.
- Bending Radius Compliance: Maintain minimum bending radius (10× static, 15× dynamic)—excessive bending damages conductors or breaks the shield, reducing signal integrity and EMI protection; avoid tight cable routing near cabinet edges.
- Connector Mating: Align connectors properly before mating—forced insertion damages gold-plated contacts, increasing contact resistance and causing intermittent communication; verify "click" sound to confirm secure connection.
- Operation & Maintenance:
- Regular Inspection: Check quarterly for:
- Jacket damage (cuts, abrasions from machinery)
- Loose connectors (common after vibration events)
- Shield drain wire corrosion (in humid environments)
Replace damaged cables immediately—exposed conductors pose shock hazards and increase EMI susceptibility.
- EMI Source Separation: Route cables away from high-voltage power lines (≥480V AC) and motor drive cables—minimum separation of 30cm reduces cross-interference; use cable trays with metal dividers for additional isolation.
- Cleaning Protocol: Wipe connectors with a lint-free cloth dampened with isopropyl alcohol—dust or oil on contacts increases resistance; avoid water or harsh solvents (damage connector insulation).
- Environmental Limitations:
- Temperature & Jacket Selection: Use PVC jackets only in -25℃~+70℃; switch to PU jackets for temperatures < -25℃ or > +70℃—PVC becomes brittle in cold, while PU offers better low-temperature flexibility and oil resistance.
- Condensing Humidity: Avoid installation in condensing humidity (>95% RH, 40℃)—condensation seeps through jacket seams, corroding conductors; use cable glands with O-rings and dehumidifiers in outdoor or humid enclosures.
- Replacement & Spare Parts:
- Genuine ABB Components: Use only genuine ABB TK801V003 (3BSC950089R1) cables—non-genuine alternatives lack proper shielding, impedance matching, and connector compatibility, leading to bus failures and potential module damage.
- Spare Inventory: Maintain 2~3 spare cables per 10 distributed modules—cable failures disconnect entire remote I/O segments; spares reduce downtime from 1+ week (delivery) to <1 hour for mission-critical systems (e.g., chemical reactor controls)
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The structure and details of the product:

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