ABB TU830V1 3BSE013234R1 Extended Module Termination Unit

The TU830V1 Extended Module Termination Unit (MTU) is a high-performance, high-density signal connection and termination unit designed by ABB for the S800 I/O system. With the product code 3BSE013234R1, it is engineered specifically for 50V application environments. Acting as a passive bridge between I/O modules and field devices, it streamlines the wiring process and enhances system reliability and maintenance convenience. The unit supports up to 16 I/O channels and two independent field process power connections, making it a core component for building compact and efficient industrial automation control cabinets.

Following a modular design philosophy, the TU830V1 utilizes mechanical coding keys to prevent the incorrect insertion of I/O modules and features built-in module locking and system grounding mechanisms, ensuring long-term stable operation in demanding industrial environments. Its design complies with multiple international electrical standards. It is widely used in power, process industries, manufacturing, and other sectors, and is compatible with various ABB control systems including 800xA, Advant OCS, and Compact Product Suite.

2. Core Product Features

1. Extensive Compatibility: Designed to work seamlessly with ABB's comprehensive range of S800 I/O modules. It is compatible with analog input modules such as AI810, AI815, AI820, AI830/AI830A, AI835/AI835A, AI843, AI845; analog output modules like AO810/AO810V2, AO815, AO820, AO845/AO845A; digital input modules including DI810, DI811, DI814, DI830, DI831, DI840, DI880, DI885; digital output modules such as DO810, DO814, DO815, DO818, DO840, DO880; and HART communication modules like DP820 and DP840. This makes the TU830V1 a highly flexible platform for building versatile I/O stations.

2. Complete Integrated Installation: The unit integrates three-wire connection terminals, fuse holders, and field power distribution into a single device. Users can complete all connections—from field signals (including I/O signals and common ZP) to process power (L+/L-)—on a single unit, significantly simplifying cabinet wiring and saving installation space and time.

3. High-Density Channel Design: A single TU830V1 unit supports up to 16 independent I/O channels. Each channel provides two I/O signal terminals (e.g., A1/B1) and one common terminal (ZP). Furthermore, it offers two independent and isolated field process power inputs (UP1 and UP2), each equipped with a 6.3A fuse, meeting multi-channel power supply requirements.

4. Reliable Mechanical and Electrical Design:

• Mechanical Coding Keys: Equipped with two six-position mechanical keys, providing a total of 36 different mechanical configuration combinations. This physically prevents mismatched I/O modules from being inserted incorrectly, enhancing system safety at the hardware level.

• Module Locking Mechanism: A built-in mechanical lock securely fastens the I/O module to the MTU. The locking action simultaneously sends a BLOCK signal release to the module, ensuring the module can only exit its initialization state and begin operation after being correctly installed and locked. This prevents faults caused by live insertion/removal or poor contact.

• DIN Rail Grounding: Features a snap-on latching device that securely mounts the unit to a standard DIN rail (35mm) and provides reliable grounding.

5. ModuleBus Integration & Address Assignment: The TU830V1 incorporates part of the ModuleBus, responsible for distributing the communication bus from the controller or previous unit to the connected I/O module and onward to the next MTU. It also automatically generates the correct physical address for the connected I/O module by processing position signals, simplifying system configuration.

3. Detailed Design and Functionality

1. Layout and Terminal Assignment

The TU830V1 utilizes a three-row (Rows A, B, C), 20-position screw terminal block (X1). Its layout is clear and functionally zoned:

• Process Power Terminals: Located at the ends of the terminal block (positions 1-2 and 19-20). Row A corresponds to L1- and L2- (power negative), Row B corresponds to L1+ and L2+ (power positive), providing connection points for two independent field power supplies. Row C positions are NC (Not Connected).

• I/O Signal and Common Terminals: Positions 3 to 18 correspond to the 16 I/O channels. Each channel occupies one position across Rows A, B, and C:

• Row A: Typically connects the field signal's "negative" or "return" line (depending on module type), labeled A1 through A16.

• Row B: Typically connects the field signal's "positive" or "signal" line, labeled B1 through B16.

• Row C: Connects the channel's Common Reference Point (ZP), labeled C1 through C16. For input modules, field power is typically provided via Row B (power positive) and Row C (ZP, power negative).

2. Power Grouping and Fuse Protection

The process power is divided into two completely electrically isolated groups: UP1 and UP2:

• Each group serves 8 consecutive I/O channels (e.g., UP1 for channels 1-8, UP2 for channels 9-16).

• Each group has its own independent L+ and L- power input terminals and is pre-equipped with a 6.3A Time-Lag glass tube fuse (5x20 mm).

• This grouped isolation design enhances system reliability, as a fault in one power group does not affect the normal operation of channels in the other group. Users should select the appropriate fuse rating based on the type and load of the connected I/O modules, referring to the recommended values in the manual.

3. Recommended Fuse Selection (Core Reference)

Depending on the type and configuration of the connected I/O modules, the TU830V1 has specific recommendations for fuse selection for each process power circuit (L1/L2). The table below summarizes key information. Strict adherence is mandatory for selection.

Table: TU830/TU830V1 Recommended Fuse Selection Guide (Based on 24V Process Power Supply)

Note 1: If 3-wire field devices are connected, their internal current consumption must be considered additionally.
Note 2: 5 x 20 mm Time-Lag (slow-blow) fuses must be used.
Note 3: For some modules (e.g., AI830/AI830A, AI835/AI835A, AI843, AO820), process power is not used; fuse selection is "Not Applicable (NA)."
Note 4: For modules like DP820, the fuse rating depends entirely on the load.

4. Application and Advantages Summary

The TU830V1 Extended Module Termination Unit is a critical component within the ABB S800 I/O system architecture. Its value is demonstrated in the following aspects:

• Enhances System Reliability: Multiple design features—such as mechanical anti-mismatch insertion, module operation interlock, grouped isolated power supply, and fuse protection—minimize the risk of human error and electrical faults, ensuring the continuous and stable operation of the control system.

• Simplifies Engineering and Maintenance: Pre-arranged terminals and clear labeling enable fast and standardized field wiring. The modular design allows for the replacement or upgrade of individual I/O modules without extensive rewiring, leading to short maintenance windows and simple operations.

• Optimizes Space Utilization: The high-density design allows for deploying more I/O points within limited cabinet space, making it particularly suitable for compact control cabinets or complex applications requiring extensive signal processing.

• Increases System Flexibility: Compatibility with nearly all types of S800 I/O modules allows users to flexibly combine modules based on specific signal types (analog, digital, HART) and point requirements, building highly customized I/O stations. It also supports ModuleBus cascade expansion.

• Compliance with Standards and Environmental Requirements: The product meets IP20 protection class, IEC insulation standards, and complies with the EU RoHS Directive (2011/65/EU), aligning with modern industry requirements for electrical safety and environmental protection.