What Is the ABB TU860?
When process downtime drives up operational costs, the ABB TU860 3BSE078710R1 provides a reliable solution. This MTU for Ethernet FCI (S800 I/O) acts as the backbone of a distributed I/O cluster, connecting up to 12 single or redundant S800 I/O modules and Module Termination Units. It hosts single or redundant Ethernet Adapters (TC810, TC811) and Ethernet FCI Communications Interface Modules (CI845s) for robust communication with AC 800M process controllers. By enabling modular expansion without rewiring, the TU860 directly reduces both initial installation and long-term maintenance expenses.
Technical Specifications That Drive ROI
- Operating Temperature Range: -40°C (-40°F) to +70°C (158°F) — this wide tolerance eliminates the need for costly climate-controlled enclosures in extreme environments, cutting capital and energy costs.
- Redundant Power Supply Connectors: Two connectors for single/redundant 24 V power supplies ensure uninterrupted operation. Redundancy minimizes unplanned downtime, which can cost thousands per hour in lost production.
- Mounting on 35 mm DIN Rail: Standardized mounting reduces installation time and labor costs compared to custom brackets.
- IP20 Protection (IEC 60529): Sufficient for clean industrial environments, avoiding the premium price of higher IP-rated enclosures where not needed.
- Pollution Degree 2 (IEC 60664-1): Suitable for typical factory floors, preventing premature failure from conductive pollution and extending service life.
These specs directly translate to lower total cost of ownership: wider temperature tolerance reduces HVAC needs, redundant power cuts downtime risk, and standard mounting speeds up deployment.
Real-World Applications
Oil & Gas Remote Terminal Units (RTUs): In remote wellhead monitoring, the TU860’s -40°C to +70°C range eliminates heated shelters, saving thousands per site. Its redundant power connectors ensure continuous data acquisition even during power fluctuations.
Water/Wastewater Treatment Plants: Distributed I/O clusters using the TU860 allow modular expansion as plant capacity grows. The ability to connect up to 12 modules per MTU reduces the number of fieldbus segments and associated cabling costs.
Pharmaceutical Batch Processing: With ATEX II 3G Ex nA IIC T5 Gc certification for hazardous areas, the TU860 can be installed in Zone 2 locations, avoiding expensive explosion-proof enclosures and reducing installation complexity.
Installation and Setup Guidance
Mount the TU860 on a standard 35 mm DIN rail inside an IP20-rated cabinet. Connect the 24 V DC power supply to either or both power connectors for redundancy. Attach CI845 FCI modules and Ethernet Adapters (TC810/TC811) to the designated slots. Use the two Modulebus connectors to link S800 I/O modules in a daisy-chain topology. Ensure proper grounding per IEC 61131-2 mechanical operating conditions to avoid noise interference. No special tools are required, keeping labor costs low.
Maintenance and Reliability
The TU860’s robust design includes corrosion resistance (G3 corrosive atmosphere compliance) and wide humidity tolerance (5 to 95% no condensation), reducing inspection frequency in harsh environments. Perform annual visual checks for dust accumulation on the IP20 enclosure and verify power supply redundancy by testing each supply independently. The MTU’s passive design (no moving parts) means minimal wear — focus maintenance on connected modules and field wiring. This reliability directly lowers spare parts inventory and unscheduled maintenance costs.
Compatibility and Integration
The TU860 integrates seamlessly with AC 800M process controllers via Ethernet FCI communication. It supports single or redundant CI845 modules and Ethernet Adapters (TC810, TC811). The two Modulebus connectors allow only S800 I/O modules to be connected, ensuring a consistent ecosystem. This compatibility reduces integration engineering hours and avoids costly protocol converters. For marine applications, DNV and ABS certifications ensure compliance without additional testing.
Selection Guide and Purchasing Advice
Before ordering the ABB TU860, verify your system voltage (24 V DC), required number of I/O modules (up to 12 per MTU), and environmental conditions (temperature, humidity, hazardous area classification). The TU860 is available at SpareTechPLC, a trusted supplier of industrial automation parts. Confirm current lifecycle status and availability with our team to ensure your project timeline stays on track. Choosing the right MTU upfront avoids costly retrofits later.
Frequently Asked Questions
Q: Can the TU860 be used in a redundant configuration?
A: Yes, the TU860 has two mounting slots for redundant Ethernet Adapters and two connectors for redundant 24 V power supplies, ensuring high availability.
Q: What is the maximum number of I/O modules I can connect?
A: The TU860 supports up to 12 single or redundant S800 I/O modules and Module Termination Units per MTU.
Q: Does the TU860 require special software for configuration?
A: Configuration is handled through the AC 800M controller engineering tool; the TU860 itself is a passive MTU that does not require separate software.
Q: What certifications does the TU860 hold for hazardous areas?
A: It carries ATEX II 3G Ex nA IIC T5 Gc and cULus for Class I, Division 2, Groups A-D T4, among others.
Q: How does the wide temperature range reduce costs?
A: The -40°C to +70°C operating range eliminates the need for heated or cooled enclosures in many outdoor or unheated indoor locations, saving on both capital and energy expenses.
