ABB TP857 3BSE030192R1

Description

Product Description

The ABB TP857 3BSE030192R1 is an advanced Fieldbus Communication Interface module designed specifically for the ABB S800 I/O system, a cornerstone of the company’s Distributed Control System (DCS) architecture. As the gateway between the I/O rack and higher-level control networks, this module is essential for seamless data exchange in modern industrial automation applications. The core function of the ABB TP857 3BSE030192R1 is to connect S800 I/O stations to PROFIBUS DP networks, acting as a slave device that enables remote I/O capabilities for ABB’s AC 800M controllers and third-party PROFIBUS masters with enhanced performance characteristics. Engineered for high reliability in demanding process environments, the ABB TP857 3BSE030192R1 features redundant communication capabilities, ensuring uninterrupted data flow even in the event of network disruptions, making it ideal for critical process applications.

Product Parameters

• Model Number: ABB TP857 3BSE030192R1

• Type: PROFIBUS DP Slave Communication Interface Module

• System Compatibility: ABB S800 I/O (Standard and Extended Line)

• Communication Protocol: PROFIBUS DP-V0/DP-V1

• Transmission Speed: 9.6 kbit/s to 12 Mbit/s (Auto-detecting)

• Redundancy Support: Dual-channel communication for redundant network configurations

• Station Addressing: Rotary switches for address configuration (0-99)

• Backplane Current Consumption: 130 mA @ 5 VDC (Typical)

• Power Dissipation: 2.5 W (Maximum)

• Mounting: Directly on S800 I/O DIN-rail mounting base (TU8xx series)

• Isolation: 500 VAC between fieldbus and internal electronics

• Indicators: Status LEDs for Power, Network Communication, Module Status, Redundancy Status, and Diagnostic Alerts

• Connectors: 9-pin D-sub female for PROFIBUS DP interface

• Operating Temperature: 0°C to 60°C

• Certification: CE, UL, CSA, ATEX (for installation in hazardous areas when properly housed)

Advantages and Features

The primary advantage of the ABB TP857 3BSE030192R1 lies in its enhanced redundancy capabilities and seamless integration with ABB’s control ecosystem while maintaining openness to third-party systems. By utilizing the ABB TP857 3BSE030192R1, engineers can distribute I/O modules across a plant floor with confidence that communication will be maintained even if one network path fails. The module supports hot-swapping of I/O modules without disturbing the fieldbus communication, a critical feature for maintaining uptime in continuous process industries. Advanced diagnostic capabilities built into the ABB TP857 3BSE030192R1 provide detailed status information about the network, redundancy status, and individual I/O channels, accessible through ABB’s engineering tools or directly via the fieldbus master. The rugged mechanical design of the ABB TP857 3BSE030192R1 ensures reliable operation in industrial environments with vibration, temperature extremes, and electrical noise. Compared to its predecessor the TP854, the ABB TP857 3BSE030192R1 offers enhanced diagnostic capabilities and improved support for redundant network architectures.

Application Cases in Application Fields

The communication capabilities of the ABB TP857 3BSE030192R1 make it essential across various process and hybrid industries requiring high-availability communication.

• Chemical Processing: In a continuous chemical plant where communication loss could lead to unsafe conditions, the ABB TP857 3BSE030192R1 with its redundant configuration connects remote I/O racks near reactor vessels to a central AC 800M controller, ensuring critical temperature and pressure monitoring is never interrupted.

• Oil and Gas Production: On an offshore platform, the ABB TP857 3BSE030192R1 enables redundant communication to wellhead I/O, ensuring that emergency shutdown signals can be transmitted reliably even if one communication path is damaged.

• Water and Wastewater Treatment: For a large municipal water treatment facility, the ABB TP857 3BSE030192R1 allows the central SCADA system to communicate with remote pump stations via redundant PROFIBUS DP networks, consolidating control and monitoring functions with high availability.

• Pharmaceutical Manufacturing: In a validated pharmaceutical facility, the ABB TP857 3BSE030192R1 ensures deterministic communication between the control system and critical process I/O, supporting the data integrity requirements of regulatory compliance with the added security of redundant communication paths.

• Mining and Minerals Processing: On a critical conveyor system, the ABB TP857 3BSE030192R1 enables distributed I/O for emergency stops and belt monitoring devices with redundant communication back to the main control room, ensuring safety functions remain operational even under fault conditions.

Comparison with Competing Products

When compared to similar fieldbus interface modules such as the Siemens ET 200M IM153-2 Redundant or the Rockwell Automation 1756-RM2, the ABB TP857 3BSE030192R1 offers distinct advantages for users already invested in ABB’s System 800xA ecosystem. While Siemens modules excel in SIMATIC environments with Profinet, the ABB TP857 3BSE030192R1 provides tighter integration with ABB’s engineering tools and asset management software while maintaining the PROFIBUS DP protocol many process facilities prefer. Compared to standard non-redundant PROFIBUS DP slave devices, the ABB TP857 3BSE030192R1 offers superior diagnostic capabilities and the critical advantage of redundant communication paths. Its ability to mix standard and intrinsically safe I/O modules on the same redundant communication network gives the ABB TP857 3BSE030192R1 a flexibility advantage in facilities with both general-purpose and hazardous area instrumentation requiring high availability.

Comparison with Predecessor (TP854)

When compared to the earlier ABB TP854 3BSE025349R1, the ABB TP857 3BSE030192R1 represents a significant evolution in capability. While the TP854 provides standard PROFIBUS DP slave functionality, the TP857 adds comprehensive support for redundant PROFIBUS networks, allowing connection to two separate fieldbus cables for automatic failover. The diagnostic capabilities of the ABB TP857 3BSE030192R1 are enhanced over the TP854, providing detailed visibility into redundancy status and network health. For new installations requiring high availability or upgrades to existing systems where communication reliability is paramount, the ABB TP857 3BSE030192R1 is the preferred choice over the non-redundant TP854.

Selection Suggestions and Precautions

When selecting the ABB TP857 3BSE030192R1 for your project, first verify compatibility with your specific S800 I/O mounting bases (TU8xx series) and your PROFIBUS master’s support for redundant slave configurations. Ensure that the firmware version of the ABB TP857 3BSE030192R1 matches the requirements of your control system, as older firmware may not support newer I/O modules or advanced diagnostic functions. Proper termination of both PROFIBUS networks is critical when installing the ABB TP857 3BSE030192R1 in redundant mode; ensure that the module is correctly addressed using the rotary switches and that bus terminators are enabled at the physical ends of both network segments. When configuring the ABB TP857 3BSE030192R1 in your engineering software, pay careful attention to the PROFIBUS baud rate settings, redundancy parameters, and GSD file compatibility. Always observe proper grounding and shielding practices for the ABB TP857 3BSE030192R1 to prevent communication errors caused by electromagnetic interference in industrial environments. Finally, test the redundancy functionality during commissioning by intentionally disconnecting each network path in turn to

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