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ABB TU849 (3BSE042560R1) Module Terminal Unit  

1. Key Parameters

• Product Model: TU849
• Order Code: 3BSE042560R1
• Product Series: ABB TU Series Modular Terminal Units (Advanced Signal Termination, Configurable Routing)
• Core Function: Provides modular termination and distribution of analog/digital signals between field devices and ABB S800 I/O modules; enables configurable signal routing for system flexibility; offers enhanced surge and ESD protection; supports diagnostic monitoring of connection health; ensures compatibility with ABB automation ecosystems
• Electrical & Signal Specifications:

  Parameter	Details	Performance Metrics
  Signal Capacity & Types	- Supported Signals: Analog Input (4~20mA, 0~10V), Analog Output (4~20mA), Digital Input (24V DC, 110V AC), Digital Output (24V DC, 230V AC) - Maximum Channels: 48 (24 input + 24 output, modularly configurable) - Rated Voltage: 24V DC (standard); 110/230V AC (optional, via interchangeable terminal blocks) - Current Rating: 10A per terminal (continuous); 20A (peak, 1s)	Accommodates diverse industrial signals in a modular design, supporting flexible system configurations and future expansions
  Protection & Isolation	- Surge Protection: ±20kV ESD (contact, IEC 61000-4-2); 3kV (line-line) and 5kV (line-ground) surge immunity (IEC 61000-4-5) - Overcurrent Protection: Replaceable 3A slow-blow fuses (per 6-channel group) with visual indication - Isolation: 3kV AC (channel-to-channel, 1min); 6kV AC (field-to-system side, 1min) - Noise Rejection: Integrated low-pass filters (1kHz cutoff) for analog signals; EMI shielding (≥80dB at 100MHz)	Advanced protection safeguards sensitive S800 I/O modules (e.g., AI893, DO820) from electrical anomalies in heavy industrial environments
  Terminal & Wiring Features	- Terminal Type: Spring-clamp (tool-less) with quick-release levers (0.2mm²~6mm² copper wire) - Terminal Configuration: Modular blocks (6 channels each) for easy replacement/upgrade - Wiring Options: Front-access with color-coded terminals (AI/AO/DI/DO); rear cable entry via M20 glands - Labeling: Removable, writable labels + barcode for asset management integration	Tool-less terminals reduce wiring time by 35%; modular blocks enable quick reconfiguration (e.g., changing from DI to AI) without full unit replacement
  Diagnostics & Monitoring	- Status Indicators: LED per 6-channel group (green = normal, red = fault) + system power LED - Diagnostic Output: Optional relay contact for fault signaling (integrates with PLC/DCS alarm systems) - Test Points: Accessible via removable terminal covers (compatible with standard test probes) - Contact Resistance: ≤8mΩ (ensures minimal signal degradation)	Group-level diagnostics enable rapid fault isolation; optional alarm relay provides real-time alerts to control systems

• Mechanical Specifications:
  • Dimensions: 110mm (W) × 230mm (L) × 55mm (H) (modular form factor)
  • Mounting Type: DIN rail (EN 50022, 35mm top-hat); panel mount (via optional brackets)
  • Housing Material: Glass-fiber reinforced polyamide (PA66+25% GF, UL 94 V0, flame-retardant)
  • Weight: Approximately 650g (without wires/fuses)
  • IP Rating: IP20 (base unit); IP54 with optional protective cover (for dusty/wet environments)
• Environmental Ratings:
  • Operating Temperature Range: -30℃~+70℃ (-22℉~158℉)
  • Storage Temperature Range: -40℃~+85℃ (-40℉~185℉)
  • Humidity Tolerance: 5%~95% RH (non-condensing, 40℃)
  • Vibration Resistance: 10~500Hz, 1.8g acceleration (IEC 60068-2-6; no terminal loosening)
  • Shock Resistance: 25g (11ms half-sine, IEC 60068-2-27; no structural damage)
• Compliance Standards: CE, RoHS, ABB S800 I/O V6.0+, IEC 61010-1, UL 508, CSA C22.2 No. 14, ATEX Zone 2 (with IP54 cover)

2. Key Features

• 48-Channel Modular Design: 6-channel interchangeable terminal blocks enable flexible configuration (e.g., 24 AI + 24 DO or 36 DI + 12 AO)—supports system reconfiguration without replacing the entire unit, reducing upgrade costs by 40% in evolving industrial processes.
• Tool-Less Spring-Clamp Terminals: Quick-release levers for 0.2mm²~6mm² wires—cut wiring time by 35% during installation and 50% during maintenance; ensures consistent contact pressure (≤8mΩ resistance) for reliable signal transmission.
• 3kV Channel Isolation: Prevents cross-talk between high-power outputs (e.g., 230V AC valves) and sensitive inputs (e.g., 4~20mA pressure sensors)—critical for maintaining measurement accuracy (±0.1% for analog signals) in noisy environments like steel mills.
• Optional IP54 Protection: Removable protective cover with IP54 rating—enables deployment in dusty (mining) or wet (food processing washdown) environments without compromising accessibility, expanding application versatility.
• Group-Level Fusing & Diagnostics: 3A fuses per 6-channel group with visual LED indicators—isolates faults (e.g., shorted DO line) to a single group, maintaining operation of other channels; reduces troubleshooting time by 60% vs. non-grouped designs.
• Wide Voltage Compatibility: Supports 24V DC, 110V AC, and 230V AC signals—eliminates the need for separate termination units for different voltage levels, simplifying cabinet design in mixed-signal applications (e.g., factory automation with legacy 110V devices).
• ATEX Zone 2 Compliance: With IP54 cover, meets explosive atmosphere requirements—enables safe deployment in hazardous areas (e.g., chemical storage facilities, oil refineries) where ignition risks exist.

3. Application Fields

• ABB S800 I/O System Integration: Primary application in modular automation architectures:
  • Chemical Plant Batch Processing: Configures as 24 AI (4~20mA pH/temperature) + 24 DO (24V DC valve controls) for reactor skids; modular blocks allow quick reconfiguration between batch recipes, reducing changeover time by 30%.
  • AC800M PLC Manufacturing Lines: Handles 36 DI (24V DC sensor signals) + 12 AO (4~20mA motor speed controls) for assembly lines; group fuses isolate a shorted sensor circuit, preventing full line shutdown during faults.
• Hazardous & Harsh Environments: Safe operation in challenging conditions:
  • Oil Refinery Storage Tanks: With IP54 cover, terminates 48 signals (level sensors, pump controls) in ATEX Zone 2 areas; 5kV surge protection withstands lightning-induced transients, ensuring reliable tank monitoring.
  • Mining Processing Plants: Connects 48 mixed signals (conveyor sensors, crusher controls) in dusty environments; rugged housing and vibration resistance (1.8g) prevent terminal loosening, maintaining ore processing uptime.
• Water & Wastewater Treatment: Managing diverse signal types:
  • Wastewater Treatment Plants: Terminates 24 AI (flow/pH sensors) + 24 DO (valve/pump controls); 3kV isolation prevents ground loops between wet well sensors and control systems, ensuring accurate treatment process control.
  • Desalination Facilities: Handles 48 signals including 230V AC pump outputs and 4~20mA pressure sensors; wide voltage support eliminates need for separate termination units, reducing cabinet complexity.
• Industrial Retrofit Projects: Upgrading legacy systems:
  • Steel Mill Modernization: Integrates with existing 110V AC limit switches and new 24V DC sensors via configurable terminals; modular design allows phased replacement of legacy termination blocks, minimizing production downtime.
  • Food & Beverage Plant Upgrades: Replaces outdated terminal strips with tool-less terminals for 48 washdown zone signals; IP54 cover resists caustic cleaners, complying with FDA hygiene standards.
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