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ABB TK801V003 3BSC950089R1 module bus extension cable

ABB TK801V003 3BSC950089R1 module bus extension cable

ABB TK801V003 3BSC950089R1 module bus extension cable

  • Item NO.:

    TK801V003 3BSC950089
  • Payment:

    T/T
  • Price:

    $600
  • Product Origin:

    Sweden
  • Color:

    NEW
  • Lead Time:

    In stock

We will arrange delivery within 3-5 days after receiving the payment.

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ABB TK801V003 (3BSC950089R1) Module Bus Extension Cable  

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:

1. Key Parameters

  • 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:
    Parameter Details Performance Metrics
    Bus Protocol Support - Supported Buses: ABB PRONET, PROFIBUS DP (for S800 I/O systems)
    - Data Transfer Rate: Up to 12Mbps (PROFIBUS); 100Mbps (PRONET, full-duplex)
    - Signal Type: Differential twisted-pair (for noise immunity)
    - Bus Latency: <1ms (per meter, at max data rate)
    Ensures real-time data transmission for time-sensitive applications (e.g., process control loops), avoiding delays that cause system instability
    Cable Electrical Characteristics - Conductor Material: Tinned copper (corrosion-resistant, 0.5mm² per conductor)
    - Conductor Count: 8 twisted pairs (4 for data, 4 for power/signaling)
    - Impedance: 100Ω ±10% (at 1MHz, for PROFIBUS/PRONET)
    - Insulation Resistance: ≥1000MΩ (at 500V DC, 25℃)
    Low impedance and high insulation resistance maintain signal integrity over long distances, reducing data packet loss to <0.01%
    Shielding & EMI Protection - Shield Type: Double-layer (aluminum foil + tinned copper braid, 90% coverage)
    - EMI Attenuation: ≥80dB (at 100MHz)
    - Common-Mode Rejection: ≥75dB (at 50/60Hz)
    - Grounding: Dedicated drain wire (22AWG) for shield grounding
    Minimizes EMI interference from industrial equipment (e.g., motor drives, transformers), critical for operation near high-noise machinery
    Connector & Mechanical Ratings - Connector Type: ABB proprietary male/female bus connectors (gold-plated contacts, IP20 rated)
    - Connector Durability: 500+ mating cycles (mechanical life)
    - Operating Voltage: 24V DC ±10% (power lines); 5V DC ±5% (signal lines)
    - Current Capacity: 2A (power lines); 0.5A (signal lines)
    Gold-plated contacts ensure low contact resistance (<50mΩ) and corrosion resistance; high mating cycles support repeated module reconfiguration
  • 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)

2. Key Features

  • 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.

3. Application Fields

  • 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.

4. Precautions

  • 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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