ABB TP867 3BSE043664R1

Product Description

The ABB TP867 (3BSE043664R1) is a Terminal and Power Interface Module for the S800 I/O system, a core component within ABB’s System 800xA and AC 800M automation architecture. This module plays a dual and critical infrastructural role: it serves as the primary termination point for field wiring connections to an S800 I/O station, and it provides the regulated 24V DC power to the I/O modules installed in the same base unit. The ABB TP867 acts as the interface between the external field devices (sensors, actuators) and the internal electronic I/O modules. It houses high-density terminal blocks for secure and organized wiring, while its integrated DC/DC converter ensures that clean, stable power is delivered from the station’s main power supply to the backplane. This combination makes the TP867 the fundamental gateway for both signals and power into the remote or local I/O station, directly impacting the station’s reliability and ease of maintenance.

Technical Parameters and Specifications

• System Compatibility: ABB S800 I/O, System 800xA, AC 800M controllers.
• Module Type: Combined Terminal and Power Supply Module for S800 I/O bases.
• Primary Functions:
  1. Termination Interface: Provides screw terminal blocks for connecting field wiring (digital and analog signals) to the I/O station.
  2. Power Conditioning: Contains a DC/DC converter that accepts a wide-range DC input and outputs a regulated, isolated 24V DC to power all I/O modules in the base.
• Power Input: Typically accepts a wide-range DC input (e.g., 19.2 – 30 V DC) from an external power supply or redundant power system.
• Power Output: Provides a specific current rating (e.g., 2A or 4A) of regulated 24V DC to the base’s backplane.
• Isolation: Provides galvanic isolation between the field wiring side, the power input, and the internal 24V bus for the I/O modules, protecting the electronics from ground loops and noise.
• Diagnostics: Features LED indicators for power input status and internal 24V output status.
• Connection: Integrated terminal blocks for field wiring and connectors for mating with the S800 I/O base.
• Redundancy Support: Can be part of a redundant power configuration. Two TP867 modules can be connected to a redundancy module to ensure uninterrupted power if one supply fails.
• Mounting: Installs directly into a dedicated slot in the S800 I/O base unit.

Advantages and Key Features

• Integrated Design for Compactness and Reliability: By combining termination and power supply in one unit, the ABB TP867 simplifies the station design, reduces the number of components, and minimizes internal wiring, leading to higher overall system reliability and a smaller footprint.
• Superior Signal Integrity and Protection: The isolation between field terminals, power input, and internal bus prevents electrical noise, ground loops, and potential surges on the field side from affecting the sensitive I/O modules.
• Organized and Secure Wiring: The high-density, clearly labeled terminal blocks provide a professional and maintainable interface for all field connections, which is crucial for commissioning, troubleshooting, and long-term reliability.
• Hot-Swappable for High Availability: The module is designed to be replaced while the system is powered and operating (hot-swap), allowing for maintenance or repair without taking the entire I/O station offline.
• Seamless Integration with S800 Ecosystem: As a native ABB component, the TP867 is mechanically and electrically optimized for the S800 base and I/O modules, guaranteeing compatibility and ensuring optimal performance without complex configuration.

Application Cases in Various Fields

• Process Skid Automation (Oil & Gas): An S800 I/O station with a TP867 module is mounted on a compressor skid. It terminates all local temperature, pressure, and vibration sensor wires and powers the analog input modules, providing a reliable data acquisition node.
• Water Treatment Plant Remote I/O: Installed in a distributed I/O cabinet near filter beds. The ABB TP867 terminates signals from level transmitters, valve limit switches, and pump contactors, powering the station that communicates via PROFIBUS DP back to the central control room.
• Packaging Machine Control Cabinet: Inside a machine panel, the TP867 provides the termination point for dozens of photoelectric sensors and solenoid valve cables, while reliably powering the high-speed digital I/O modules that control the machine sequence.
• Power Plant Balance of Plant (BOP): Used in a motor control center (MCC) to interface with motor starters, temperature switches, and flow meters, consolidating signals onto a single network segment.

Comparison with Competing Products

Compared to solutions from other DCS/PLC vendors, the ABB TP867 represents a specific, integrated architectural approach:

• Integrated vs. Separate Components: In systems like Siemens ET 200SP, the terminal block (TM) and power supply (PS) are typically separate modules. The TP867 combines these functions, offering a different trade-off between modularity and pre-integrated simplicity. The ABB approach can save space and reduce part numbers.
• S800 System-Specific Design: Its value is maximized within the ABB S800 and AC 800M ecosystem. Competing remote I/O from Rockwell (Point I/O/ ArmorBlock) or Schneider (Advantys) have their own distinct power and termination schemes. They are not cross-compatible.
• Focus on Process Industry Standards: The design, with its emphasis on isolation, diagnostics, and hot-swap capability, is tailored for the high availability and harsh electrical environments common in continuous process industries.
• Simplified Engineering: For an ABB system integrator, specifying a TP867 is a standardized step. It ensures the power and termination needs of a base are met with a single, qualified component, reducing engineering time and risk.

Selection Suggestions and Precautions

1. Correct Base Unit Matching: The ABB TP867 is designed for specific S800 base units. Verify the base unit model (local or remote) to ensure physical and electrical compatibility before ordering.
2. Accurate Power Budget Calculation: Critically important. Calculate the total 24V DC current consumption of all I/O modules intended for the base unit. Ensure the TP867‘s output current rating (e.g., 2A) exceeds this total with a safety margin (typically 25-30%). Also, size the external primary power supply accordingly.
3. Plan for Redundancy if Critical: For applications where loss of the I/O station would cause a process shutdown or safety issue, implement a redundant power supply configuration using two TP867 modules with an ABB redundancy interface module.
4. Proper Field Wiring Practices: Use the correct wire gauge for the current and distance. Follow ABB’s installation guidelines for grounding cable shields (usually at the marshalling cabinet end only) to maintain the isolation benefits. Ensure terminal screws are tightened to the specified torque.
5. Observe Hot-Swap Procedures: While designed for hot-swapping, always follow the documented procedure for safe removal and insertion to prevent electrical arcing or communication disruption to other modules in the base.
6. Spare Parts Strategy: Given its role as a critical power and signal gateway, keeping a spare ABB TP867 (3BSE043664R1) module on-site for critical processes is highly recommended to minimize mean time to repair (MTTR). Ensure the spare matches the exact specification. When replacing, verify that the new module’s power rating is identical to the original.