Product Core Brief
- Model:
- Full OEM Part Code: 3BSE028602R1
- Brand: ABB
- Series: S800 Distributed I/O for Freelance 800F, Symphony Plus DCS
- Core Function: 8-channel high-capacity mechanical relay digital output, each channel independent galvanic isolation; directly drives large contactors, heavy-duty shutdown solenoids, heater loads and high-power alarm horns without intermediate relays. Equipped with hot-swap, per-channel diagnosis and OSP output safe state function for process safety interlock systems.
- Matching Terminal Base: TU880 dedicated heavy-load screw terminal MTU base
- Key Specs: 8 Form-A NO relay channels, full per-channel isolation; contact rating 10A resistive @230VAC / 10A @24VDC; full hot-swap support; OSP safety state; Condition: New Original / New Surplus
Product Introduction
ABB (3BSE028602R1) is high-power relay output flagship module of ABB S800 I/O series, oriented to heavy industrial scenarios such as thermal power auxiliary equipment, metallurgical rolling mill interlocks, chemical plant emergency shutdown systems.Compared with standard 5A DO820 relay module, single channel contact capacity is doubled to 10A, which can directly switch high-power AC loads and eliminate a large number of intermediate relay cabinets, saving control room layout space and wiring cost.Every relay channel adopts independent isolation design, 1500V AC withstand voltage between field high-voltage circuit and DCS internal logic, completely isolate ground loop interference caused by potential difference of multi-point field equipment.Built-in OSP safety logic: When Modulebus or PROFIBUS-DP communication is interrupted, all relays automatically switch to user preset safe state to avoid dangerous misoperation of process equipment. Support online hot-swap maintenance without cutting off rack power, effectively shorten equipment maintenance downtime. Each channel is equipped with independent status and fault LED, and fault information can be uploaded to DCS operator station in real time.
Key Technical Specifications
| Parameter | Value |
|---|---|
| Full Order Code | 3BSE028602R1 ( high-power relay output module) |
| Applicable DCS Platform | Freelance 800F, Symphony Plus S800 I/O system |
| Matched Terminal Base | TU880 heavy-duty screw terminal MTU unit |
| Channel Configuration | 8 independent Form-A normally open relay channels, per-channel galvanic isolation |
| Relay Contact Rating | 10 A resistive load @ 230 V AC; 10 A @ 24 V DC |
| Minimum Switching Load | 1 mA / 5 V DC to guarantee weak signal contact reliability |
| Galvanic Isolation Standard | Per-channel field-to-logic isolation, 1500 V AC 1 minute withstand |
| Communication Bus | Modulebus backplane, PROFIBUS-DP via CI840A interface |
| Safety OSP Function | Software configurable relay safe state under communication failure |
| Diagnostic Functions | Relay drive fault, module undervoltage, bus communication loss alarm |
| Hot Swap Performance | Full hot-swap supported, no rack power-off required |
| Backplane Power Consumption | Typ. 160 mA, Max. 200 mA (5 V DC backplane supply) |
| Max Power Dissipation | 5.2 W with all 8 relays fully energized |
| Front Panel Indicators | RUN green LED, FAULT red LED, 8 yellow channel relay status LEDs |
| PCB Coating Grade | ISA-S71.04 G3 anti-corrosion conformal coating standard |
| Operating Ambient Temp | 0 ℃ ~ +55 ℃ continuous operation; derate 15% above 50 ℃ full load |
| Storage Temperature Range | -40 ℃ ~ +70 ℃, 5–95% RH non-condensing |
| Mechanical Dimensions | W27 mm × H119 mm × D96 mm |
| Net Unit Weight | 0.32 kg |
| Compliance Certifications | CE EMC, cULus Class I Div 2, ATEX II 3G Zone 2 hazardous location certified |
Quality Control Process
- Incoming Verification: Cross-check serial number and full part code 3BSE028602R1 against ABB spare database; inspect backplane connector pins, relay contact spring tightness, PCB free of cold solder joints and oxidation. Reject modules with damaged anti-static packaging.
- 24h Full Load Aging Bench Test: Install on TU880 terminal base, connect to Freelance test controller, each channel loaded with 230VAC 10A resistive load, continuous relay pull-in/release cycle aging. Simulate bus disconnection to verify OSP safe state switching function, record backplane voltage every 15 minutes.
- Insulation Withstand Test: 500V Megger isolation test for each relay channel between field contact circuit and control logic circuit, pass threshold ≥10 MΩ; verify backplane reverse polarity protection function.
- Firmware Calibration: Read onboard I/O firmware version via Control Builder M engineering software, calibrate relay drive fault detection threshold and OSP parameter group.
- Final Packaging Protection: Cover backplane edge connector with plastic dust cap; pack module with anti-static foam, attach dated QC Pass label before factory carton delivery.
Replacement Pitfall Guide
❗Terminal Base Mismatch Risk: must be matched with dedicated TU880 terminal base; ordinary TU830V1 cannot bear 10A heavy load current, which will cause terminal overheating and burnout.❗Inductive Load Surge Damage Risk: Contactors, solenoids and other inductive loads must install external RC absorption loops; without surge suppression, relay contacts will be ablated by reverse voltage spikes and fail prematurely.❗Contact Overload Permanent Failure Risk: Strictly control single channel load not to exceed 10A resistive load; long-term overload will lead to relay contact adhesion and uncontrollable equipment action.❗Unconfigured OSP Safety Hidden Danger: If OSP relay safe state is not set in engineering software, communication interruption will keep the original relay state, which may trigger safety accidents such as accidental startup of heavy equipment.❗ESD Damage Internal Drive Chip: Wear grounded anti-static wristband and touch cabinet earth bar for 3 seconds before hot-swap replacement; static discharge will damage relay drive optocoupler, resulting in permanent channel output failure.
Compatibility Matrix & Benchmarks
Compatibility Matrix
- -XC anti-corrosion variant ↔ Standard 3BSE028602R1: Direct hot-swap replacement; XC version thickened salt-fog coating for coastal power and offshore chemical plants.
- TU880 heavy-duty screw terminal base: Mechanical lock fit, large-current wiring terminals, fully matched signal and power circuit of .
- CI840A PROFIBUS-DP communication interface: Realize remote distributed I/O layout, unified configuration through Control Builder M.
- DO820 5A standard relay module: Same rack mechanical size, but insufficient contact capacity for heavy loads, cannot replace .
- AC500 S500 DO524 PLC transistor output module: Incompatible, different backplane bus protocol, no high-power relay isolation function.
Performance Benchmarks
- Full 8-channel relay synchronous refresh cycle: < 1.8 ms
- Relay pull-in action delay: ≤ 12 ms from DCS logic command output
- OSP safe state switching time after bus disconnection: ≤ 200 ms
- Rated mechanical service life of relay contacts: ≥ 8 million times under full 10A resistive load
