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ABB TU835 Extension Module Termination Unit

1. Product Overview

2. Core Specifications

3. Key Functions

3.1 High-Capacity Signal Expansion

• 64-Channel Termination: 32 dual-channel terminals deliver 33% more capacity than TU831 (48 channels)—paired with a TU847 (64 channels) creates a 128-channel termination system in one S800 I/O rack, eliminating the need for extra racks (saves 40% cabinet space).
• Seamless Primary Unit Integration: Connects to TU840/TU841/TU847 via ABB extension cables (e.g., 3HAC031685-002) — shares the same wiring logic and DCS configuration, avoiding signal misrouting during expansion.

3.2 Enhanced Signal Protection & Load Handling

• High-Current Support: 15A continuous current per terminal (vs. TU831’s 10A) and 0.2–4.0mm² wire compatibility enable termination for mid-power devices (e.g., 24V DC/12A conveyor motors, 10A solenoid valves) that exceed TU831’s capacity.
• Reinforced Isolation: 1kV (channel-channel)/2kV (signal-ground) isolation eliminates cross-talk between high-power digital signals (e.g., 24V DC/15A) and sensitive analog signals (e.g., 4-20mA pressure readings), ensuring ±0.05% measurement accuracy for critical processes (e.g., petrochemical reactor control).
• Optional Surge Protection: Dedicated slots for ABB TPS802 surge modules (IEC 61643-1 compliant) — clamps voltage spikes (e.g., lightning-induced surges) to <250V DC, protecting I/O modules from permanent damage.

3.3 Efficient Maintenance & Troubleshooting

• Dual Test Points per Channel: Each channel has two 4mm test ports (voltage/current) — technicians can measure signal values (e.g., 8V from a level sensor, 10mA from a flow meter) without wire disconnection, cutting troubleshooting time by 60% vs. TU831.
• Unified Labeling: Color-coded terminals (analog: blue; digital: gray) and etched numbering (1–64) align with ABB primary units, minimizing wiring errors during expansion or module replacement.
• Field-Module Isolation: Field wires connect to front terminals; prefabricated link cables link to S800 I/O modules — replacing a faulty I/O module takes <3 minutes (no field wire removal).

4. Typical Applications

• Power Plant Main Control: Expands a TU847’s 64 channels by 64, terminating 128 signals (64 AI: turbine speed/pressure; 64 DI: breaker status) for a 1000MW coal-fired power plant’s main control rack.
• Petrochemical Refinery: Adds 64 channels to an S800 I/O rack, connecting 32 4-20mA flow meters (crude oil pipelines) and 32 24V DC/12A control valves in a distillation unit.
• Metallurgical Mill: Supports 64 digital signals (proximity sensors, emergency stops) for a hot rolling mill’s conveyor network, extending a primary TU841 to cover the entire line’s safety and control signals.

5. Usage Notes

1. Wire & Load Guidelines:
   • For 2.5–4.0mm² wires (high-current signals), use a torque screwdriver (1.0–1.2N·m) to secure terminals (over-tightening damages spring clamps).
   • Do not exceed 15A per terminal — use external contactors for devices >15A (e.g., 20A motors).
2. Extension Cable Requirement: Use only ABB-approved extension cables (e.g., 3HAC031685-002) — third-party cables cause isolation failures or signal loss.
3. Surge Module Installation: In harsh environments (e.g., outdoor substations), install TPS802 modules and ground to a dedicated earth bar (resistance ≤0.5Ω).
4. Clearance & Cooling: Maintain ≥50mm clearance around the unit; avoid mounting near heat sources (e.g., resistors) to prevent overheating in high-temperature cabinets.
5. Configuration Mapping: Align the TU835’s channel numbering with the DCS via Control Builder M (match primary unit logic) to ensure accurate signal routing

The structure and details of the product：

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