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ABB TU848 (3BSE042558R1) Termination Unit 

1. Key Parameters

• Product Model: TU848
• Order Code: 3BSE042558R1
• Product Series: ABB TU Series Advanced Termination Units (High-Density Signal Management, Enhanced Protection)
• Core Function: Terminates and distributes high-density analog/digital signals between field devices and ABB S800 I/O modules; provides advanced surge and ESD protection; supports modular expansion for system scalability; enables diagnostic monitoring of signal health; ensures compatibility with ABB automation ecosystems
• Electrical & Signal Specifications:

  Parameter	Details	Performance Metrics
  Signal Capacity & Compatibility	- Supported Signals: Analog (4~20mA, 0~10V), Digital (24V DC, 110V AC), thermocouple (Type K/J/T), RTD (PT100) - Maximum Channels: 64 (32 input + 32 output, configurable) - Rated Voltage: 24V DC (standard), 110V AC/DC (optional, via terminal blocks) - Current Handling: 8A per terminal (continuous); 15A (peak, 1s)	Accommodates diverse signal types in a single unit, supporting complex industrial processes with mixed sensor/actuator requirements
  Protection Features	- Surge Protection: ±25kV ESD (contact, IEC 61000-4-2); 4kV (line-line) and 6kV (line-ground) surge immunity (IEC 61000-4-5) - Overcurrent Protection: Individual 2A slow-blow fuses for each 8-channel group (replaceable without tools) - Isolation: 2.5kV AC (channel-to-channel); 5kV AC (field-to-system side, 1min) - Noise Suppression: Integrated ferrite filters on all signal lines (100kHz~1GHz attenuation ≥60dB)	Advanced protection safeguards sensitive S800 I/O modules (e.g., AI893, RTD810) from extreme electrical anomalies in heavy industrial environments
  Terminal & Wiring Design	- Terminal Type: Push-in spring terminals (tool-less, 0.14mm²~4mm² copper/aluminum wire) - Terminal Pitch: 3.5mm (high-density) with color-coded blocks (AI/AO/DI/DO) - Wiring Options: Front/rear access; removable terminal blocks for pre-wiring - Labeling: Laser-etched channel IDs + QR code for digital documentation access	Tool-less push-in terminals reduce wiring time by 40% vs. traditional designs; high-density layout saves 30% cabinet space vs. standard termination units
  Diagnostics & Monitoring	- Status Indicators: LED per 8-channel group (green = normal, red = fault, yellow = warning) + system health LED - Diagnostic Interface: Optional 2-wire communication port for integration with 800xA DCS (fault logging, remote monitoring) - Test Points: Gold-plated test jacks for each channel (compatible with standard probes) - Contact Resistance: ≤5mΩ (per terminal, ensures minimal signal loss)	Integrated diagnostics enable predictive maintenance; remote monitoring via 800xA reduces on-site inspection requirements by 50%

• Mechanical Specifications:
  • Dimensions: 120mm (W) × 250mm (L) × 60mm (H) (high-density form factor)
  • Mounting Type: DIN rail (EN 50022, 35mm); direct mounting to S800 I/O racks (via adapter)
  • Housing Material: Glass-fiber reinforced polyamide (PA66+30% GF, UL 94 V0, flame-retardant)
  • Weight: Approximately 750g (without wires/fuses)
  • IP Rating: IP20 (front panel); IP40 with optional protective cover
• Environmental Ratings:
  • Operating Temperature: -40℃~+70℃ (-40℉~158℉)
  • Storage Temperature: -55℃~+85℃ (-67℉~185℉)
  • Humidity Tolerance: 5%~95% RH (non-condensing, 40℃)
  • Vibration Resistance: 10~500Hz, 2g acceleration (IEC 60068-2-6; no terminal loosening)
  • Shock Resistance: 30g (11ms half-sine, IEC 60068-2-27; no structural damage)
• Compliance Standards: CE, RoHS, ABB S800 I/O V6.1+, IEC 61010-1, IEC 61326-3-1, UL 508, CSA C22.2 No. 14 |

2. Key Features

• 64-Channel High-Density Design: Supports 64 mixed analog/digital signals in a compact footprint—ideal for space-constrained control cabinets in large-scale plants (e.g., refineries with 1000+ I/O points), reducing rack count by 30% compared to standard termination units.
• Advanced Surge & ESD Protection: ±25kV ESD and 6kV line-ground surge immunity—protects against extreme electrical events (e.g., lightning strikes in outdoor installations, high-voltage transients in steel mills) that would damage standard termination units.
• Tool-Less Push-In Terminals: Accept 0.14mm²~4mm² wires with secure push-in connection—cuts wiring time by 40% during initial installation and 60% during maintenance rework; eliminates torque errors common with screw terminals.
• Removable Terminal Blocks: Enables pre-wiring in workshops before on-site installation—reduces on-site commissioning time by 50% in complex systems (e.g., 800xA DCS for chemical plants with thousands of I/O points).
• 2.5kV Channel Isolation: Prevents cross-talk between sensitive signals (e.g., thermocouple measurements) and high-power outputs (e.g., valve actuators)—ensures measurement accuracy (±0.05% for RTD signals) in noisy industrial environments.
• Integrated Diagnostics: Group LEDs + optional 800xA communication—provides real-time fault detection (e.g., blown fuse, surge event) and historical logging, enabling predictive maintenance and reducing unplanned downtime by 25%.
• Extreme Temperature Range (-40℃~+70℃): Operates reliably in arctic, desert, and high-temperature industrial zones—eliminates the need for heated/cooled enclosures in harsh environments (e.g., offshore platforms, mining sites).

3. Application Fields

• Large-Scale Process Plant I/O Termination: Primary application in high-density automation systems:
  • Refinery 800xA DCS Integration: Terminates 64 mixed signals (32 AI for pressure/temperature + 32 DO for valve controls) in a crude distillation unit; 2.5kV isolation prevents interference between high-power valves and sensitive analytical sensors, ensuring precise process control.
  • Chemical Plant Batch Processing: Handles 64 channels including thermocouples (Type K) and 24V DC actuators; removable terminal blocks enable pre-wiring for quick skid-to-cabinet connections during batch line reconfigurations.
• Heavy Industrial Environments: Withstanding extreme conditions:
  • Steel Mill Hot Rolling Control: Terminates 32 RTD signals (roll temperature) and 32 DO signals (cooling water valves); 6kV surge protection withstands transients from rolling mill drives, while -40℃~+70℃ range handles mill ambient temperatures.
  • Mining Underground Systems: Connects 64 signals (gas detectors, conveyor controls) in humid, dusty tunnels; rugged construction and vibration resistance (2g) prevent terminal loosening, ensuring safety-critical monitoring.
• Energy & Infrastructure Projects: Supporting critical signal integrity:
  • Nuclear Power Plant Auxiliaries: Terminates 64 safety-related signals (pressure transmitters, pump status); 5kV field-to-system isolation complies with IEC 61513 nuclear safety standards, preventing cross-contamination between safety and non-safety circuits.
  • Offshore Oil Platforms: Handles 64 mixed signals (subsea valve controls, topside sensors); wide temperature range and humidity tolerance (-40℃~+70℃, 95% RH) withstand marine environments, while surge protection guards against lightning.
• High-Availability Manufacturing: Ensuring reliable production lines:
  • Automotive Body Shop Robotics: Terminates 64 DI/DO signals (welding robot sensors, fixture controls); diagnostic LEDs quickly identify faulty connections, reducing line downtime from hours to minutes during changeovers.
  • Semiconductor Fab Cleanrooms: Connects 64 precision AI signals (wafer temperature, vacuum pressure); low contact resistance (≤5mΩ) ensures measurement accuracy, critical for nanoscale manufacturing processes.
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