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The ABB TU838 is a premium high-density extension termination unit designed for ABB’s AC 800M DCS and S800 I/O platforms. As a advanced expansion solution (upgraded from TU837), it focuses on maximized channel capacity, broad signal versatility, and extreme environmental resilience—engineered to extend signal termination for large-scale, safety-critical I/O racks. It seamlessly integrates with primary termination units (e.g., TU847) or high-performance S800 I/O modules (including AI840 for RTD, DI840 for high-speed digital signals), supporting standard analog/digital signals, specialized industrial signals (RTD, pulse, high-speed digital), and high-current loads. Ideal for ultra-demanding scenarios: large-scale nuclear power plant control systems, offshore petrochemical platforms, and heavy-duty mining machinery—where signal counts exceed 96 channels, and reliable operation under extreme temperatures, humidity, or vibration is non-negotiable.
- 128-Channel Expansion: 64 dual-channel terminals deliver 33% more capacity than TU837 (96 channels)—paired with a TU847 (64 channels) creates a 192-channel termination system in one S800 I/O rack, eliminating the need for 3+ additional racks and reducing cabinet space by 60%.
- Specialized Signal Support: Beyond standard analog/digital signals, it handles 100Ω/1000Ω RTDs (e.g., PT100/PT1000 temperature sensors) and 1MHz high-speed digital/pulse signals (e.g., encoder feedback for precision motor control, high-frequency flow meters)—enabling integration with high-performance field devices that lower-tier units cannot accommodate.
- Wide Temperature & Vibration Tolerance: Operates at -40°C~+85°C (survives arctic offshore winters or desert mining summers) and resists 2g vibration (IEC 60068-2-6)—stable performance in mobile machinery (e.g., mining excavators) or offshore platforms with structural vibration.
- Offshore-Grade Protection: Optional IP54 enclosure (with corrosion-resistant aluminum housing) and DNV GL certification—withstands salt spray, humidity (95% RH non-condensing), and dust, making it suitable for offshore oil/gas platforms.
- SIL 2 Compliance: Meets IEC 61508 SIL 2 standards for safety-related loops—ideal for critical systems (e.g., nuclear power plant coolant flow monitoring, offshore emergency shutdown valves) where failure could lead to safety hazards.
- High Isolation & EMC Immunity: 1.5kV channel-to-channel and 2.5kV signal-to-ground isolation eliminates cross-talk between high-power digital signals (e.g., 20A motor controls) and sensitive RTD/pulse signals. EN 61000-6-2 "industrial+" EMC protection resists interference from offshore radar, mining power cables, or nuclear plant instrumentation.
- Overload & Surge Protection: Built-in overload protection (triggers alarm at >20A per terminal) and dedicated slots for ABB TPS803 surge modules (clamps voltage spikes to <200V DC)—prevents terminal burnout and protects S800 I/O modules from lightning or power surges.
- Dual Test Points & LED Diagnostics: Each channel has two 4mm test ports (voltage/current/resistance for RTDs) for non-intrusive 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%.
- Color-Coded & Numbered Terminals: Color markers (analog: blue; digital: gray; RTD: red; pulse: yellow) and etched numbering (1–128) align with ABB primary units, minimizing wiring errors during expansion.
- Hot-Swap Terminal Blocks: Damaged terminal blocks can be replaced without powering down the DCS—critical for 24/7 processes (e.g., offshore oil production) where downtime is costly.
- Offshore Petrochemical Platform: Expands a TU847’s 64 channels by 128, terminating 192 signals (64 RTD: pipeline temperature; 64 high-speed digital: pump encoder feedback; 64 DO: valve controls) — IP54 enclosure resists salt spray, DNV GL compliance meets offshore standards.
- Mining Excavator Control: Supports 128 signals (48 AI: hydraulic pressure; 40 DI: safety interlocks; 40 pulse: motor encoder feedback) — vibration resistance and -40°C~+85°C range handle mining site conditions.
- Nuclear Power Plant Auxiliary System: Adds 128 channels to an S800 I/O rack, connecting 64 PT100 RTDs (coolant temperature) and 64 DI/DO (safety valve status/control) — SIL 2 compliance ensures safety loop reliability.
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Wire & Load Management:
- For 2.5–6.0mm² high-current wires, use a torque screwdriver (1.2–1.5N·m) to secure terminals—over-tightening damages 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).
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RTD & High-Speed Signal Wiring:
- For RTDs: Use 3-wire/4-wire shielded cables (≤100m) to eliminate lead resistance errors; pair with S800 AI840 modules for accurate temperature measurement.
- For 1MHz pulse signals: Use twisted-pair shielded cables (impedance 100–120Ω) and keep length ≤50m to avoid signal degradation.
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Offshore/Harsh Environment Setup:
- Install the IP54 enclosure (ABB part no. 3HAC032014-001) and use marine-grade shielded cables—seal cable entries with waterproof glands (ABB part no. 3HAC032101-001) to prevent saltwater ingress.
- Conduct quarterly corrosion inspections (clean terminals with isopropyl alcohol) to maintain performance in salt spray environments.
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Safety Compliance:
- For SIL 2 loops, use only ABB-approved extension cables (3HAC031685-005) and verify isolation resistance (≥100MΩ) with an insulation tester (e.g., ABB MI2077) before commissioning.
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Maintenance Scheduling:
- Test surge modules (TPS803) annually via Control Builder M—replace if the yellow "SURGE" LED is lit.
- In vibration-prone applications (mining), retighten terminal screws every 6 months to prevent loosening from constant vibration
The structure and details of the product：
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