Description
Detailed Parameter Table
| Parameter Name | Parameter Value |
| Product Model | ABB TC625 |
| Manufacturer | ABB |
| Product Category | Termination Board / Signal Conditioning Unit |
| Compatible I/O Modules | AI8x0, AO9x0, DI8x0, DO8x0 Series |
| Channels Supported | 16 channels (8 for AI/AO, 16 for DI/DO) |
| Terminal Type | Spring Clamp (0.2–4 mm² / AWG 24-12) |
| Isolation Voltage | 500 V AC (channel-to-channel) |
| Surge Protection | 25 V (inputs), 60 V (outputs) |
| Fuse Protection | Group fusing (8 channels per fuse) |
| HART Support | Yes (AI/AO channels) |
| Operating Temperature | -40°C to +85°C |
| Installation | DIN Rail (TS35) |
| Safety Certification | IEC 61131-2, UL 508 |
| Ingress Protection | IP20 (front) |
ABB TC625
Product Introduction
The ABB TC625 is a universal termination board designed for ABB’s Symphony® Plus and 800xA distributed control systems. Serving as the critical junction between field devices and ABB’s I/O modules, this high-density board provides secure signal conditioning, galvanic isolation, and fused protection for analog/digital signals. Engineered for maximum flexibility, the ABB TC625 supports mixed I/O configurations within a single unit – accommodating everything from 4-20 mA transmitters to discrete solenoid valves while ensuring signal integrity.
As the backbone of ABB’s S+ I/O architecture, the ABB TC625 features intelligent channel grouping and tool-less wiring to streamline cabinet build-outs. Its core function is to eliminate ground loops, suppress electromagnetic interference (EMI), and provide configurable fail-safe paths for safety-critical applications. The ABB TC625 transforms raw field connections into reliable, noise-free interfaces for upstream modules like AI830 and DO810, making it indispensable for maintaining signal accuracy in harsh industrial environments.
Core Advantages and Technical Highlights
The ABB TC625 delivers superior signal management with industry-leading flexibility:
Universal Channel Configuration: Supports mixed analog/digital signals in any combination. Each channel accepts 0.2–4 mm² wires without tools, while color-coded zones simplify AI/AO/DI/DO grouping. Reconfigurable in minutes during commissioning.
Enhanced Signal Integrity: Triple-shielded terminal blocks with 500 V channel isolation eliminate cross-talk. Gold-plated signal paths maintain <1 mΩ contact resistance after 100+ insertion cycles, ensuring long-term accuracy for mV-level signals (e.g., thermocouples).
Intelligent Fault Containment: Group fusing (8 channels/fuse) protects upstream I/O modules from field shorts. Integrated TVS diodes clamp induced surges from solenoid coils or lightning strikes. Channel-level LEDs instantly identify open circuits or blown fuses.
HART® Signal Optimization: Dedicated low-impedance paths (<250 Ω) preserve HART® 7 communication on 4-20 mA loops. Ferrite beads suppress RF interference from VFDs, enabling reliable smart device diagnostics.
Extreme Environment Resilience: Operates at -40°C to +85°C with 93% humidity tolerance. Salt-spray tested per IEC 60068-2-52 for offshore deployments. Vibration-resistant to 5 g (10-150 Hz).
Maintenance-Optimized Design: Front-accessible test points allow live signal measurement without disconnection. Slide-out fuse trays enable replacement in <30 seconds. Backward-compatible with legacy Harmony TBs.
Typical Application Scenarios
The ABB TC625 excels in high-density I/O applications requiring signal integrity:
Power Plant Turbine Halls: Terminates 500+ signals from bearing vibration sensors, lube oil pressure switches, and servo valve feedbacks. Group fusing prevents turbine trip during localized field faults.
Automotive Paint Shops: Routes PT100 signals from curing ovens and discrete outputs to robotic painters. Gold contacts resist chemical corrosion from solvent vapors.
Wastewater SCADA Cabinets: Interfaces 4-20 mA flowmeter outputs and pump run-status contacts. IP20 protection prevents dust-induced shorts in aerated grit chambers.
Pharmaceutical Cleanrooms: Connects CIP (clean-in-place) conductivity sensors and steam valve outputs. EMI filtering prevents false signals from variable speed mixer drives.
Mining Conveyor Systems: Handles belt speed analog inputs and emergency stop digital inputs. Spring clamps maintain connection integrity despite 5 g vibrations.
ABB TC625
Related Model Recommendations
ABB AI830: 8-channel analog input module; pairs with TC625 for temperature/pressure monitoring.
ABB DO810: 16-channel digital output module; drives actuators via TC625‘s fused outputs.
ABB TA620: Compact termination board; extends TC625 capacity in space-limited cabinets.
ABB HTTA-01: S+ I/O rack chassis; houses up to 12x TC625 boards.
ABB CI854: PROFIBUS interface; integrates TC625-terminated signals into PLC networks.
ABB SD822: Surge protection module; enhances lightning protection for TC625 field connections.
Installation, Commissioning and Maintenance Instructions
Installation Preparation: Mount ABB TC625 on 35 mm DIN rail with end retainers. Maintain 30 mm clearance above board for airflow. Use tinned copper conductors only. Strip wires to 9±0.5 mm. Disconnect field power before inserting modules. Verify fuse ratings match I/O specifications (0.5A for AI, 2A for DO).
Maintenance Suggestions: Semi-annually, verify spring tension using 0.2–4 mm² test wire. Clean terminals with fiberglass brush if oxidation observed. Quarterly, check fuse continuity with multimeter. Monitor channel LEDs: solid red indicates open circuit. Replace fuses only with ABB-specified types (F1: 0.5A, F2: 2A). For HART® networks, confirm loop impedance >230 Ω.
Service and Guarantee Commitment
ABB warrants the ABB TC625 for 36 months against material and manufacturing defects. Global technical support includes 24/7 access to ABB’s Ability™ Collaborative Operations Center for wiring schematics and troubleshooting guides. On-site validation services ensure proper grounding and EMC compliance. Spare parts remain available for 20+ years post-discontinuation. The product carries UL 508, IEC 61131-2, and ATEX Category 3 certifications, with documentation provided. ABB’s lifecycle management guarantees firmware compatibility across Symphony Plus generations and offers migration kits for INFI-90 systems.
