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The ABB TU847 is an advanced modular termination unit engineered exclusively for ABB’s AC 800M Distributed Control System (DCS) and S100 I/O platforms. As an upgraded variant of the TU846, it specializes in high-density, secure termination of field signals (analog, digital, and high-current) while adding enhanced diagnostic and surge protection capabilities. Its core role is to act as a robust interface between field wiring (sensors, actuators, motors) and ABB I/O modules (e.g., AI830, DI810, DO810, AO810), simplifying wiring management, accelerating troubleshooting, and protecting sensitive DCS components. It is ideal for large-scale industrial applications (petrochemicals, power generation, metallurgy) where high I/O density, signal integrity, and minimal downtime are critical.
The TU847 addresses the limitations of the TU846 by supporting more channels and higher currents:
- 64-Channel Capacity: 32 dual-channel terminals (vs. 24 in TU846) enable termination of 64 field signals in a single unit—reducing rack space by 33% for large I/O systems (e.g., 192 channels need 3× TU847 vs. 4× TU846).
- High-Current Support: Handles up to 15A continuous current per terminal (vs. 10A in TU846), making it suitable for high-power field devices (e.g., 24V DC solenoid valves, small motors) that exceed the TU846’s capacity.
- Wide Conductor Compatibility: Accepts 0.2–4.0mm² wires (tool-free for 0.2–2.5mm², screwdriver-assisted for 2.5–4.0mm²) — compatible with thick cables for high-current applications (e.g., 10 AWG for 15A loads).
Built for harsh industrial environments, it provides superior shielding for critical signals:
- Reinforced Electrical Isolation: Channel-to-channel (1kV AC) and signal-to-ground (2kV AC) isolation (double the TU846’s channel isolation) eliminates cross-talk between high-power digital signals (e.g., 24V DC/10A) and sensitive analog signals (e.g., 4-20mA pressure readings), ensuring ±0.05% signal accuracy.
- Integrated Surge Protection Slots: Dedicated slots for ABB TPS802 surge protection modules (compatible with IEC 61643-1) — no need for external enclosures. The TPS802 clamps voltage spikes (e.g., lightning-induced surges) to <250V DC, protecting I/O modules from permanent damage.
- EMI Shielding: Metalized plastic housing reduces electromagnetic interference (EMI) from nearby power cables (common in power plants) — critical for analog signals prone to noise (e.g., 0-10V temperature sensors).
The TU847 streamlines maintenance with built-in diagnostic features:
- Dual Test Points per Channel: Each channel has two test ports (voltage/current) compatible with 4mm probes — technicians can measure both signal voltage (e.g., 5V from a sensor) and current (e.g., 8mA) without disconnecting wires, cutting troubleshooting time by 60% vs. the TU846.
- LED Status Indicators:
- Green "POWER" LED: Illuminates when the optional surge protection module is powered.
- Red "SURGE" LED: Lights if a surge event triggers the TPS802 module (indicates need to replace the surge protector).
- Yellow "FAULT" LED: Flashes for open circuits or short circuits in field wiring (e.g., a broken sensor cable).
- Diagnostic Dry Contact: A dedicated digital output (normally open) connects to an AC 800M DI module (e.g., DI810) — triggers SCADA/HMI alarms (e.g., "TU847 Channel 23 Short Circuit") for remote monitoring.
- Field-to-Module Isolation: Field wires connect to front terminals; prefabricated ABB link cables (e.g., 3HAC031684-001) connect the TU847’s back to I/O modules. Replacing a faulty I/O module takes <3 minutes (no field wire disconnection), vs. 30+ minutes for direct wiring.
- Stackable Design: Multiple TU847 units mount side-by-side in AC 800M/S100 racks (19-inch standard) — supports up to 256 channels (4× TU847) per rack, matching the capacity of large DCS systems (e.g., a 1000MW power plant’s boiler control I/O rack).
- High-Temperature Endurance: -30°C~+70°C operating range (vs. TU846’s -25°C~+70°C) enables use in extreme environments (e.g., arctic oil pipelines, desert solar power plants).
- Use Case: Terminates 64 signals (32 AI, 32 DO) for a crude distillation unit’s AC 800M rack.
- Configuration: TU847 with TPS802 surge modules; DO channels power 24V DC/8A control valves (within 15A capacity).
- Value: 64-channel density saves rack space; surge protection resists voltage spikes from nearby pump motors.
- Use Case: Manages 128 signals (64 AI, 64 DI) in an S100 I/O rack for turbine speed monitoring.
- Configuration: 2× TU847 units; AI channels terminate 4-20mA encoder signals (±0.05% accuracy via enhanced isolation); DI channels monitor emergency stop contacts.
- Value: Dual test points enable quick verification of encoder signals; -30°C~+70°C range works in unheated turbine enclosures.
- Use Case: Terminates 64 DO signals for 24V DC/12A motor starters in a hot rolling mill.
- Configuration: TU847 with 4.0mm² wires (for 12A current); linked to DO810 I/O modules.
- Value: 15A terminal capacity handles motor inrush current; EMI shielding prevents noise from mill power cables.
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Wiring Best Practices
- For high-current signals (≥10A), use 2.5–4.0mm² stranded copper wires; torque terminals to 1.0–1.2N·m (over-tightening damages spring clamps).
- Separate analog (blue-labeled) and digital (gray-labeled) channels — avoids EMI interference.
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Surge Protection Installation
- Insert TPS802 modules into dedicated slots; connect the module’s ground terminal to the cabinet’s protective earth bar (resistance ≤0.5Ω) — ensures surge current is safely diverted.
- Replace TPS802 modules immediately if the red "SURGE" LED is lit (they are single-use after a surge event).
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Test Point Safety
- Use insulated 4mm probes (ABB part no. 3HAC030957-001) — uninsulated probes risk shorting high-current channels (15A) and causing arc flashes.
- Disconnect the link cable to the I/O module before applying test voltages >30V DC (prevents module damage).
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Compatibility Check
- Use only ABB-approved link cables (e.g., 3HAC031684-001) — third-party cables may have incorrect pinouts, leading to signal loss or short circuits.
- Ensure I/O modules support the TU847’s current capacity (e.g., DO810 modules handle up to 5A per channel; pair with high-current DO modules for 10–15A loads).
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Environmental Protection
- In dusty environments (e.g., cement plants), install the optional IP40 adapter (ABB part no. 3HAC032011-001) — prevents dust accumulation on terminals, which causes poor conductivity
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