Product Overview
The Honeywell TC-FOR081 is a relay digital output module engineered for demanding industrial automation environments. It provides eight isolated Form A (normally open) electromechanical relays, each capable of switching a wide range of loads. This module is designed to deliver reliable performance in applications where robust switching and electrical isolation are critical. Whether you are upgrading an existing control system or building a new one, the TC-FOR081 offers the flexibility and durability required for continuous operation.
Technical Specifications Breakdown
Key parameters for the TC-FOR081 are listed below for quick reference:
| Feature | Specification |
|---|---|
| Output Type | Relay Digital Output |
| Number of Outputs | 8 Form A isolated (normally open) electromechanical relays |
| Output Voltage Range | 5-30V dc @ 2.0A resistive; 48V dc @ 0.5A resistive; 125V dc @ 0.25A resistive; 125V ac @ 2.0A resistive; 240V ac @ 2.0A resistive |
| Output Current Rating (Resistive) | 2A @ 5-30V dc; 0.5A @ 48V dc; 0.25A @ 125V dc; 2A @ 125V ac; 2A @ 240V ac |
| Output Current Rating (Inductive) | 2.0A steady state @ 5-30V dc, L/R = 7ms; 0.5A steady state @ 48V dc, L/R = 7ms; 0.25A steady state @ 125V dc, L/R = 7ms; 2.0A steady state, 15A make @ 125V ac, PF = cos q = 0.4; 2.0A steady state, 15A make @ 240V ac, PF = cos q = 0.4 |
| Power Rating (Steady State) | 250W max for 125V ac resistive; 480W max for 240V ac resistive; 60W max for 30V dc resistive; 24W max for 48V dc resistive; 31W max for 125V dc resistive; 250VA max for 125V ac inductive; 480VA max for 240V ac inductive; 60VA max for 30V dc inductive; 24VA max for 48V dc inductive; 31VA max for 125V dc inductive |
| Isolation Voltage | 2550V dc for 1s between any 2 sets of contacts; 2550V dc for 1s customer load to logic; 2550V dc for 1s customer load to 24V dc supply; 850V dc for 1s customer 24V dc supply to logic |
| Output Signal Delay | 8ms maximum (OFF to ON); 26ms maximum (ON to OFF) |
| Flexbus Current (max) | 69mA @ 5V dc |
| Power Dissipation | Maximum 5.5W |
| Thermal Dissipation | Maximum 18.8 BTU/hr |
| Indicators | 8 yellow status indicators (field side indication, logic driven) |
| Keyswitch Position | 9 |
| Initial Contact Resistance | 30mΩ |
| Switching Frequency | 1 operation/3s (0.3Hz at rated load) max |
| Operate/Release Time | Maximum 10ms |
| Bounce Time | 1.2ms (mean) |
| Minimum Contact Load | 100µA at 100mV dc |
| Expected Life of Electrical Contacts | Minimum 100,000 operations @ rated loads |
| Fusing | Use a fused terminal base with a 3.0A Littelfuse 239003. Module outputs are not fused. If external fusing is desired, you must provide external fusing. |
| Max Inrush Current | 15A |
| External dc Power Supply Voltage | 24V dc nominal |
| Voltage Range | 19.2 to 31.2V dc (includes 5% ac ripple) |
| Supply Current | 125mA maximum |
| Dimensions (HxWxD) | 46mm x 94mm x 53mm (1.8in x 3.7in x 2.1in) |
| Operational Temperature | 0 to 55°C (32 to 131°F) |
| Storage Temperature | -40 to 85°C (-40 to 185°F) |
| Relative Humidity | 5 to 95% non-condensing |
| Shock (Operating) | 12g peak acceleration, 11(±1)ms pulse width |
| Shock (Non-operating) | 50g peak acceleration, 11(±1)ms pulse width |
| Vibration Tested | 2g @ 10-500Hz per IEC 68-2-6 |
| Conductors Wire Size | 12 gauge (4mm²) stranded maximum; 3/64 inch (1.2mm) insulation maximum |
Industry Applications
The TC-FOR081 is well-suited for a variety of industrial control applications. Its ability to switch both AC and DC loads makes it a versatile choice for controlling solenoids, relays, and small motors. The high isolation voltage (2550V dc) ensures safe operation in environments where electrical noise or potential ground loops exist. Common applications include:
- Process Control Systems: Use the module to actuate valves, alarms, or indicator lights in chemical or petrochemical plants.
- Material Handling: Control conveyor motors or sorting actuators where reliable switching is essential.
- Building Automation: Manage HVAC dampers or lighting circuits, leveraging the module's ability to handle both AC and DC loads.
Installation & Setup Guidance
Proper installation is key to ensuring reliable operation. Begin by verifying that the module is correctly seated in the I/O chassis. Connect the external 24V dc power supply (19.2 to 31.2V dc) to the designated terminals. For output wiring, use 12 gauge (4mm²) stranded wire with insulation thickness not exceeding 3/64 inch (1.2mm). Ensure that all connections are tight and that the module is properly grounded according to your system's guidelines.
When connecting loads, observe the output voltage and current ratings. For inductive loads, consider using snubber circuits to limit voltage spikes. The module includes a snubber circuit (off-state leakage 1mA), but external protection may be needed for severe inductive loads. Always follow your system's wiring diagram and local electrical codes.
Maintenance & Reliability
The TC-FOR081 is designed for long-term reliability, with an expected contact life of at least 100,000 operations at rated loads. To maintain optimal performance, inspect the module periodically for signs of overheating or physical damage. Keep the surrounding environment within the specified operational temperature (0 to 55°C) and humidity (5 to 95% non-condensing) ranges. Ensure that the module is kept free of dust and contaminants.
Regularly check that all terminal connections remain tight. If the module is used in a high-vibration environment, the shock and vibration ratings (12g operating, 2g @ 10-500Hz) indicate it can withstand typical industrial conditions, but periodic re-torquing of connections is recommended.
Compatibility & Integration
The TC-FOR081 is part of the Honeywell series of I/O modules and is designed to integrate with Honeywell control systems. It communicates via the Flexbus backplane, drawing a maximum of 69mA @ 5V dc from the bus. The keyswitch position (9) ensures proper addressing within the system. For detailed integration instructions, refer to your Honeywell system documentation.
Selection Guide & Purchasing Advice
When selecting the TC-FOR081 for your application, consider the load types and voltage levels you need to switch. The module's wide voltage range (5-30V dc to 240V ac) makes it a flexible choice. Ensure that your system's power supply can provide the required 24V dc at 125mA maximum. If you need assistance with compatibility or availability, contact AutoDCSTech. We offer genuine Honeywell parts and can help you find the right solution for your control system.
Please verify current lifecycle status and availability with AutoDCSTech before ordering.
Troubleshooting & Common Issues
If the module fails to operate correctly, check the following:
- No output switching: Verify that the module is receiving power (24V dc) and that the logic signals are present. Check the status indicators (8 yellow LEDs) to see if the outputs are being commanded on.
- Outputs not energizing: Ensure that the load is within the specified voltage and current ratings. Check for blown fuses in the terminal base (use 3.0A Littelfuse 239003).
- Intermittent operation: Inspect wiring connections for looseness. Verify that the module is within the operational temperature range.
- Contact wear: If the module has been in service for many operations, contact resistance may increase. Replace the module if necessary.
For persistent issues, consult the system documentation or contact AutoDCSTech for technical support.
Availability & Condition at AutoDCSTech
| Part Number | TC-FOR081 |
|---|---|
| Availability | In Stock |
| Condition | New |
| Warranty | One Year |
| Origin | US |
