ABB DO880 3BSE028602R1 High Integrity DO Module

The ABB Ability™ System 800xA® is a globally leading distributed control system (DCS) and automation platform, renowned for its exceptional openness, scalability, and high reliability. It is widely applied in power, process industries, marine, mining, and metallurgy, among other sectors. As a vital component of the system's S800 I/O series, the DO880 High Integrity Digital Output Module is designed for industrial applications with stringent demands for safety and availability. It is a 16-channel digital output module certified for SIL 3 (IEC 61508) and Category 4 (EN 954-1) safety standards. Supporting both single and redundant configurations, it provides a powerful, reliable, and easily diagnosable output solution for critical control loops.

The core mission of the DO880 module is to ensure control commands are executed accurately, safely, and continuously to field actuators (such as valves, solenoid valves, relays, indicator lights) in complex industrial environments. Its built-in advanced diagnostics and protection functions not only ensure process safety but also significantly enhance system maintainability and reduce unplanned downtime. It is the ideal choice for building highly available and highly safe automation systems.

2. Key Features and Benefits

The DO880 module integrates several advanced technologies designed to meet all high-level requirements of modern industrial automation for output modules.

1. High Channel Density & Flexible Configuration

• 16 Output Channels: A single module provides 16 independent 24V DC current-sourcing output channels within one isolated group, enabling high-density layout and saving cabinet space.

• Single/Redundant Configurations: Users can select from various Mounting Termination Units (MTUs) supporting either single or redundant configurations based on application safety and availability needs, offering flexible deployment.

2. Exceptional Safety and Integrity

• SIL 3 / Cat. 4 Certified: The module is certified for SIL 3 according to the international functional safety standard IEC 61508 and for Category 4 according to the machinery safety standard EN 954-1. It is suitable for Safety Instrumented Systems (SIS) and critical control loops requiring the highest safety integrity.

• Fault-Tolerant Design: The output drivers feature a Fault Tolerance of 1 (as defined in IEC 61508). This means that even if a single output driver fails, outputs in a "Normally De-energized (ND)" system can still be controlled, significantly improving system availability.

• Intrinsic Safety: The module itself is designed as non-intrinsically safe and must be used with certified isolators or similar devices for hazardous area applications.

3. Comprehensive Diagnostics and Monitoring

• Advanced On-board Diagnostics: The module performs comprehensive cyclic self-diagnostics, detecting and categorizing faults for reporting:

• External Errors: e.g., external power supply faults, field loop faults (short circuit, open circuit).

• Internal Channel Errors: e.g., short circuits, open circuits, or stuck-at faults affecting specific channels.

• Module Errors: e.g., internal power supply, microcontroller, FPGA, or memory faults.

• Non-Pulsing Switch Diagnostics: Capable of diagnosing the health of output switches without pulsing the output to the field, preventing unintended process disturbances.

• Loop Monitoring: Monitors the load status of each output loop. Short-circuit and open-circuit detection is effective in both energized and de-energized states. The monitoring range for loop resistance is configurable from 50 Ω to 2 kΩ, adapting to different load types and cable lengths.

• Intuitive Status Indication: The module front provides 4 module-level LEDs (F, R, W, Status) and one dual-color LED per channel (Yellow/Red). Yellow indicates an activated output, Off indicates a de-energized output, and Red indicates a channel error, enabling instant fault localization.

4. Robust Protection Features

• Current Limiting & Short-Circuit Protection: Each channel features current limiting, protecting both field devices and the module itself in case of a short circuit.

• Over-temperature Protection: Output switches are protected against over-temperature and will automatically switch off if the safe temperature threshold is exceeded.

• Degraded Mode: For "Normally Energized (NE)" channels (supported from product release PR:G onwards), a degraded mode can be entered upon fault detection to prevent unintended actions.

• Inductive Load Suppression: Built-in suppression circuitry protects the switches from voltage spikes generated by switching off inductive loads (e.g., relay coils).

5. High Reliability & Environmental Ruggedness

• Wide Voltage Range: Supports a wide supply voltage range of 19.2 - 32 V DC, accommodating field voltage fluctuations.

• Long-Distance Drive: Supports field cable lengths up to 600 meters (656 yards), meeting the wiring needs of large plants.

• Robust Environmental Specifications: Operating temperature range 0 to +55°C, storage temperature -40 to +70°C, protection class IP20, complying with stringent industrial standards (EMC, vibration, pollution degree, etc.).

• Extensive Industry Certifications: Possesses multiple certifications including CE, cULus, ATEX Zone 2, and marine classifications (ABS, BV, DNV, LR), making it suitable for demanding applications across various industries worldwide.

3. Application Areas

Thanks to its high safety integrity, powerful diagnostics, and reliability, the DO880 module is suitable for numerous industries and applications with strict requirements for control output:

• Process Industries: Control of critical valves and solenoid valves in Safety Instrumented Systems (SIS), Emergency Shutdown (ESD) systems, and Fire & Gas (F&G) systems in oil & gas, chemical, petrochemical, pharmaceutical, and water treatment industries.

• Power Generation: Output circuits for safety interlocks and critical equipment control in thermal power, nuclear power, and renewable energy plants.

• Marine & Shipbuilding: Critical control functions such as propulsion control, steering gear control, and alarm systems.

• Mining & Metallurgy: Critical equipment control in conveyor safety systems, blast furnace control systems, etc.

• Infrastructure: Systems requiring high availability assurance, such as tunnel ventilation and subway environmental control.

4. Installation and Configuration

The DO880 module must be installed on an S800 Mounting Termination Unit (MTU) compatible with the System 800xA. The MTU provides the interface to the field wiring terminal blocks or connectors.

1. Configuration Selection:

• Single Configuration: Suitable for applications requiring high safety but relatively lower redundancy demands. Optional MTUs include: TU810/TU814 (Compact), TU812 (Compact, with D-Sub 25-pin connector), TU830/TU833 (Extended).

• Redundant Configuration: Suitable for applications demanding the highest availability and fault tolerance. Two DO880 modules are installed in parallel on a pair of redundant MTUs (e.g., TU842/TU852 for horizontal mounting or TU843 for vertical mounting). If one module or channel fails, the system can seamlessly switch to the backup module, ensuring uninterrupted control.

2. Wiring Guidelines:

• Shielded cables must be used for field connections, with the shield properly grounded on the control cabinet side to optimize EMC performance.

• For inductive loads, it is recommended to connect a free-wheeling diode or RC snubber in parallel with the load and ensure the load's time constant (L/R) is less than 3ms to guarantee the accuracy of the loop monitoring function.

• Refer to the "Process Connections" tables in the manual for detailed terminal assignments to ensure correct connection of power supplies (L1+/L1-, L2+/L2-) and each channel's output wire.