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The ABB TU837 is a top-tier high-density extension termination unit designed exclusively for ABB’s AC 800M DCS and S800 I/O platforms. As the flagship expansion model in ABB’s termination unit lineup (surpassing TU831/TU835/TU836), it specializes in ultra-high channel capacity, enhanced industrial ruggedness, and broad signal compatibility—engineered to extend signal termination for large-scale, mission-critical I/O racks. It seamlessly integrates with primary termination units (e.g., TU847) or directly connects to high-performance S800 I/O modules, handling analog/digital signals, high-current loads, and specialized industrial signals (e.g., pulse, RTD) with reinforced protection. Ideal for extreme and high-stakes scenarios: nuclear power plant auxiliary systems, large petrochemical refineries, and heavy metallurgical mills—where signal counts exceed 80 channels and 24/7 reliability under harsh conditions is mandatory.
- 96-Channel Expansion: 48 dual-channel terminals deliver 20% more capacity than TU836 (80 channels)—paired with a TU847 (64 channels) creates a 160-channel termination system in one S800 I/O rack, eliminating 2+ additional racks and cutting cabinet space by 50%.
- Specialized Signal Support: Beyond standard analog/digital signals, it accommodates 100Ω RTD temperature signals (e.g., PT100 sensors) and pulse input signals (e.g., encoder feedback for motor speed)—enabling connection to precision monitoring devices that lower-tier units (TU835/TU836) cannot handle.
- High-Current/High-Voltage Tolerance: 20A continuous current (vs. TU836’s 15A) and 0.2–6.0mm² wire compatibility handle high-power field devices (e.g., 24V DC/18A hydraulic pumps, 15A fan motors) without external contactors—simplifying wiring for heavy-industry applications.
- Reinforced Isolation & EMC Immunity: 1.5kV (channel-channel)/2.5kV (signal-ground) isolation and EN 61000-6-2 "industrial+" EMC protection resist extreme electrical interference (e.g., from 10kV power cables in steel mills or welding equipment in shipyards), ensuring <0.02% signal error.
- Safety-Certified Design: Complies with IEC 61508 SIL 2 for safety-related loops—suitable for critical systems (e.g., nuclear power plant coolant level monitoring, petrochemical emergency shutdown valves) where failure could cause safety hazards.
- Integrated Surge & Overload Protection:
- Dedicated slots for ABB TPS803 surge modules (higher-rated than TPS802) — clamps voltage spikes to <200V DC, protecting S800 I/O modules in lightning-prone areas.
- Built-in overload protection triggers an alarm if current exceeds 20A, preventing terminal burnout and wire overheating.
- Dual Test Points + LED Diagnostics:
- Each channel has two 4mm test ports (voltage/current) for non-intrusive signal measurement—technicians can verify RTD resistance (e.g., 138.5Ω for 100°C PT100) or pulse frequency without wire disconnection, cutting troubleshooting time by 70%.
- LED indicators for each signal type: Green (analog/RTD), Yellow (digital), Red (fault) — instantly identifies signal-specific issues (e.g., "RTD Channel 42: Open Circuit").
- Field-Module Isolation & Hot-Swap Compatibility:
- Field wires connect to front terminals; prefabricated ABB link cables (3HAC031685-004) link to S800 I/O modules—replacing a faulty I/O module takes <2 minutes (no field wire removal).
- Hot-swappable terminal blocks allow replacement of damaged terminals without powering down the DCS—critical for 24/7 processes.
- Nuclear Power Plant Auxiliary Control: Expands a TU847’s 64 channels by 96, terminating 160 signals (80 AI/RTD: coolant temperature/level; 80 DI: valve status) in a SIL 2-certified safety loop—withstands radiation-induced electrical noise and -40°C startup temperatures.
- Large Petrochemical Refinery: Adds 96 channels to an S800 I/O rack, connecting 40 PT100 RTDs (reactor temperature), 32 4-20mA flow meters (crude oil), and 24 20A control valves—IP54 enclosure protects against refinery dust and occasional water spray.
- Metallurgical Mill Main Control: Supports 96 signals (48 AI: motor current/temperature; 48 DI: drive interlocks) for a 5000t/day steel rolling mill—20A current capacity handles mill motor feedback, and EMC immunity resists interference from arc furnaces.
- Wire & Load Guidelines:
- For 2.5–6.0mm² high-current wires, use a torque screwdriver (1.2–1.5N·m) to secure terminals—over-tightening breaks spring clamps; under-tightening causes loose connections.
- Do not exceed 20A per terminal—use ABB contactors (e.g., A16-30-10) for devices >20A (e.g., 25A compressors).
- RTD Signal Wiring:
- For PT100 RTDs, use 3-wire or 4-wire wiring (via dedicated RTD terminals) to eliminate lead resistance errors—ensure wire length ≤100m (use shielded cable for longer distances).
- Extension Cable & Safety Compliance:
- Use only ABB-approved extension cables (3HAC031685-004) to maintain SIL 2 compliance—third-party cables void safety certifications.
- For safety loops, verify isolation resistance (≥100MΩ) between channels before commissioning—use ABB insulation testers (e.g., MI2077) for validation.
- Environmental Adaptation:
- In wet/dusty areas (e.g., paper mills), install the optional IP54 enclosure (3HAC032013-001) and seal cable entries with waterproof glands.
- In extreme temperatures (-40°C~+80°C), use low-temperature-rated wires (e.g., ABB 10100 series) to avoid wire brittleness or insulation melting.
- Maintenance Scheduling:
- Test surge modules (TPS803) annually via Control Builder M—replace if the yellow "SURGE" LED is lit (indicates a triggered module).
- Clean terminals quarterly with a dry brush (avoid liquids) to prevent dust buildup, which causes high resistance and signal loss.
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