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ABB TU836 Extension Module Termination Unit

1. Product Overview

2. Core Specifications

3. Key Functions

3.1 Ultra-High-Capacity Signal Expansion

• 80-Channel Termination: 40 dual-channel terminals deliver 25% more capacity than TU835 (64 channels)—paired with a TU847 (64 channels) creates a 144-channel termination system in one S800 I/O rack, eliminating the need for additional racks and reducing cabinet space by 45%.
• Multi-Signal Compatibility: Supports current-sinking signals (0-20mA) alongside standard analog/digital signals, enabling connection to specialized field devices (e.g., high-precision weighing sensors, pulse counters) that TU835 cannot accommodate.

3.2 Reinforced Protection & Signal Integrity

• Industrial-Grade EMC Immunity: Complies with EN 61000-6-2 (high-level EMC protection) — resists interference from nearby high-voltage cables, motors, or welding equipment (common in power plants/metallurgical mills), ensuring stable signal transmission.
• High-Current & Voltage Tolerance: 15A continuous current and 600V AC/DC voltage rating handle mid-power devices (e.g., 24V DC/12A conveyor motors, 10A hydraulic valves) without external contactors, simplifying wiring.
• Integrated Surge Protection Slots: Dedicated slots for ABB TPS802 surge modules (IEC 61643-1 compliant) — clamps voltage spikes (e.g., lightning-induced surges) to <250V DC, protecting sensitive S800 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 both signal voltage (e.g., 5V from a level sensor) and current (e.g., 12mA from a flow meter) without disconnecting wires, cutting troubleshooting time by 60% vs. TU835.
• Status LED Indicators:
  • Green "POWER": Illuminates when the unit is powered.
  • Yellow "SURGE": Flashes if a surge event triggers the TPS802 module (indicates need for module replacement).
  • Red "FAULT": Lights for terminal short circuits or open circuits (e.g., broken sensor cables).
• Field-Module Isolation: Field wires connect to front terminals; prefabricated ABB link cables (e.g., 3HAC031685-003) link to S800 I/O modules — replacing a faulty I/O module takes <3 minutes (no field wire removal).

4. Typical Applications

• Power Plant Turbine Control: Expands a TU847’s 64 channels by 80, terminating 144 signals (72 AI: turbine speed/pressure/vibration; 72 DI: valve status/emergency stops) for a 1500MW gas turbine’s main control rack.
• Petrochemical Reactor Safety Loops: Adds 80 channels to an S800 I/O rack, connecting 40 4-20mA analytical sensors (pH, flammable gas) and 40 24V DC/12A emergency shutdown valves in a Zone 2 hazardous area (with IP40 adapter).
• Metallurgical Mill Main Drive: Supports 80 signals (40 AI: motor temperature/current; 40 DI: drive status) for a hot rolling mill’s main motor control system—EMC immunity resists interference from mill power cables.

5. Usage Notes

1. Wire & Load Management:
   • For 2.5–4.0mm² high-current wires, 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 fans).
2. Extension Cable Authenticity: Use only ABB-approved extension cables (e.g., 3HAC031685-003) — third-party cables cause isolation failures or signal misrouting.
3. Surge Module Installation: In lightning-prone areas (e.g., outdoor substations), install TPS802 modules and ground to a dedicated earth bar (resistance ≤0.5Ω) for optimal protection.
4. Environmental Adaptation:
   • In dusty environments (e.g., cement plants), use the optional IP40 adapter (ABB part no. 3HAC032011-001) to prevent particulate buildup on terminals.
   • Maintain ≥50mm clearance around the unit for airflow—critical in high-temperature cabinets (e.g., turbine control rooms) to avoid terminal overheating.
5. Configuration Alignment: Map the TU836’s 80 channels to the AC 800M DCS via Control Builder M (match primary unit logic) to ensure accurate signal routing and avoid DCS communication errors

The structure and details of the product：

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