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The ABB TU890 is a specialized high-density module termination unit engineered for ABB’s AC 800M DCS and S900 I/O platforms—designed to address the demands of large-scale, high-performance industrial process control. Unlike standard termination units (e.g., TU844/TU845), it focuses on ultra-high channel density, broad signal compatibility, and seamless integration with high-end S900 I/O modules (e.g., AI930, DI930). It serves as a centralized interface for diverse field signals (analog, digital, RTD, high-speed pulse) and high-power actuators, making it ideal for mission-critical, large-scale scenarios: large petrochemical refineries, thermal power plant main control systems, and metallurgical mill central control rooms—where signal counts exceed 64 channels and require unified, reliable termination.
- 64-Channel Capacity: 32 dual-channel terminals deliver 33% more channels than TU845 (48 channels)—enabling centralized termination for large I/O racks (e.g., 64 signals for a power plant’s boiler control loop) without additional units, saving 40% cabinet space.
- Broad Signal Support: Beyond standard analog/digital signals, it handles 100Ω/1000Ω RTDs (e.g., PT100/PT1000 for high-precision temperature monitoring) and 2MHz high-speed pulse signals (e.g., encoder feedback for turbine speed control)—eliminating the need for specialized termination modules and simplifying system architecture.
- 20A Continuous Current: Supports mid-to-high-power field devices (e.g., 24V DC/18A hydraulic pumps, 15A fan motors) via 0.2–6.0mm² wire compatibility—no external contactors required, reducing wiring complexity for heavy-industry applications.
- Reinforced Isolation & EMC Immunity: 1.5kV channel-to-channel and 2.5kV signal-to-ground isolation prevents 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 10kV power cables (in power plants) or arc furnaces (in metallurgical mills), ensuring <0.02% signal error.
- Surge Protection Readiness: Dedicated slots for ABB TPS803 high-performance surge modules (IEC 61643-1 compliant)—clamps voltage spikes (e.g., lightning-induced surges in outdoor substations) to <200V DC, protecting expensive S900 I/O modules from permanent damage.
- Dual Test Points + RTD Resistance Measurement: Each channel has two 4mm test ports—technicians can measure voltage, current, and RTD resistance (e.g., 138.5Ω for 100°C PT100) without disconnecting wires, cutting troubleshooting time by 70% vs. conventional units.
- Integrated LED Diagnostics:
- Green "POWER": Illuminates when the unit is powered.
- Yellow "SURGE": Flashes if a surge event triggers the TPS803 module (alerts for module replacement).
- Color-coded signal LEDs (Analog: Blue; Digital: Gray; RTD: Red; Pulse: Yellow): Solid for normal signal, flashing for weak signal/open circuit.
- Hot-Swap Terminal Blocks: Damaged terminal blocks can be replaced without powering down the DCS—critical for 24/7 processes (e.g., refinery continuous production) where downtime is costly.
- Works with both S900 (high-performance) and S800 (standard) I/O modules—enabling seamless upgrades from legacy S800 systems to S900 without replacing termination units, reducing retrofitting costs by 30%.
- Thermal Power Plant Boiler Control: Terminates 64 signals (32 AI/RTD: boiler temperature/pressure; 32 DO: fuel valve/feedwater pump control) — 20A capacity handles feedwater pump motors, and EMC immunity resists interference from generator cables.
- Large Petrochemical Refinery: Connects 32 PT1000 RTDs (distillation tower temperature) and 32 2MHz pulse signals (crude oil flow meters) to S900 I/O modules — optional IP54 enclosure protects against refinery dust and occasional water spray.
- Metallurgical Mill Central Control: Supports 64 signals (32 AI: rolling mill motor current/temperature; 32 DI: emergency stops) — 40A peak current tolerance handles motor inrush surges, and wide temperature range (-40°C~+80°C) adapts to mill heat.
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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 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).
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RTD & High-Speed Pulse Wiring:
- For RTDs: Use 3-wire/4-wire shielded cables (≤150m for PT1000) to eliminate lead resistance errors; pair with S900 AI940 modules for ±0.01°C accuracy.
- For 2MHz pulse signals: Use twisted-pair shielded cables (impedance 100–120Ω) and limit length to 80m—longer cables cause signal degradation (e.g., pulse missing).
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Surge & Environmental Protection:
- In lightning-prone areas (e.g., outdoor power plant substations), install TPS803 surge modules and ground to a dedicated earth bar (resistance ≤0.5Ω).
- In wet/dusty environments (e.g., steel mills), use the optional IP54 enclosure (ABB part no. 3HAC032015-001) and seal cable entries with waterproof/dust-proof glands.
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Compatibility & Configuration:
- When used with S800 modules, verify pinout alignment via ABB’s "S800-S900 Termination Guide"—avoid incorrect wiring that causes module damage.
- Map the TU890’s 64 channels to the AC 800M DCS via Control Builder M, ensuring signal types (analog/digital/RTD) match I/O module configurations.
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Maintenance Scheduling:
- Test surge modules annually via Control Builder M—replace if the yellow "SURGE" LED is lit.
- In high-vibration environments (e.g., mills), retighten terminal screws every 6 months and clean terminals quarterly with a dry brush to prevent dust buildup
The structure and details of the product：
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