ABB TK807F Supply Cable: AC500 S500 I/O Wiring Accessories, Specs & Availability

Technical Dossier

Product Details And Specifications

ABB TK807F Series: Comprehensive Wiring Accessory Range and Technical Overview

The ABB TK807F is a supply cable designed for use within the ABB AC500 programmable logic controller platform, specifically interfacing with the S500 distributed I/O module family. The AC500/S500 system is one of ABB's primary PLC architectures deployed across global heavy industry sectors including petrochemical refineries, nuclear auxiliary systems, pulp and paper mills, water treatment facilities, and offshore oil and gas platforms. The TK807 cable series provides the physical power interconnection layer between S500 I/O terminal units and their associated field wiring infrastructure, enabling modular, scalable control cabinet builds. These accessories are critical to the long-term serviceability of installed AC500 systems, many of which have operational lifespans exceeding 20 years.

The Evolution of TK807 Architecture

The ABB AC500 platform was introduced in the early 2000s as a successor to ABB's earlier Advant and MASTERPIECE controller families. The S500 I/O subsystem was designed from the outset for distributed installation, supporting both local and remote I/O configurations via fieldbus protocols including PROFIBUS-DP, CANopen, DeviceNet, and Modbus RTU. The TK807 cable series was developed in parallel with the S500 terminal unit (TU) range to standardize power supply connections across the modular I/O rack architecture.

Early AC500 deployments (circa 2003–2008) used the first-generation S500 I/O modules with fixed terminal units. The introduction of the AC500-eCo and AC500-S (safety) variants expanded the platform scope, requiring updated cabling accessories to support higher current ratings and safety-rated wiring segregation. The TK807F specifically addresses supply cable requirements for standard S500 terminal units, with variants covering different cable lengths and connector configurations to accommodate varying cabinet depths and DIN rail layouts.

As the AC500 platform has matured into its second decade of deployment, the TK807 cable range has transitioned from active production to managed availability status for many sub-variants. Replacement and lifecycle extension sourcing has become a primary procurement challenge for maintenance engineers operating legacy AC500 installations.

ABB TK807F Full Catalog & Functionalities (SKU List)

The following SKUs represent the verified TK807 supply cable range and associated AC500 S500 wiring accessories. Each model is classified by function within the AC500 I/O architecture:

Supply Cables — TK807 Series

• TK807F: Supply cable for S500 I/O terminal units; standard length; connects power bus to TU505/TU516/TU531 series terminal units.
• TK807G: Extended-length supply cable variant for S500 terminal units; accommodates deeper cabinet configurations.
• TK807H: Short supply cable for compact S500 rack installations; used where DIN rail spacing is minimized.
• TK807A: Supply cable, early-generation variant; compatible with first-generation S500 TU5xx terminal units.
• TK807B: Supply cable with modified connector pitch; used in specific regional cabinet standards.
• TK807C: Supply cable for S500-eCo terminal units; lower current rating than TK807F.
• TK807D: Supply cable for S500 safety (AC500-S) terminal units; segregated wiring for SIL-rated installations.
• TK807E: Intermediate-length supply cable; bridges TK807C and TK807G length specifications.

Terminal Units — TU5xx Series (Compatible Hosts)

• TU505: 8-slot S500 terminal unit; standard DIN rail mount; primary host for TK807F supply cable.
• TU516: 16-slot S500 terminal unit; extended I/O capacity; requires TK807F or TK807G supply cable.
• TU531: 8-slot S500 terminal unit with integrated bus termination; compatible with TK807F.
• TU532: 16-slot S500 terminal unit with bus termination; uses TK807F/TK807G supply cables.
• TU551: S500 terminal unit for PROFIBUS-DP coupler modules; supply cable interface via TK807 series.
• TU552: S500 terminal unit for CANopen coupler; TK807 supply cable required for power rail connection.
• TU553: S500 terminal unit for DeviceNet coupler; TK807-series supply cable compatible.

Associated Wiring Accessories

• TK501: Flat ribbon cable for S500 I/O module-to-terminal unit signal connection; used alongside TK807F in full rack assemblies.
• TK502: Extended flat ribbon cable; for remote I/O signal wiring in distributed S500 configurations.
• TK811V015: Prefabricated signal cable, 1.5 m; used for AC500 CPU to S500 I/O local bus connection.
• TK811V030: Prefabricated signal cable, 3.0 m; extended reach for distributed cabinet layouts.
• TK811V050: Prefabricated signal cable, 5.0 m; maximum standard length for local bus extension.

Sourcing Hard-to-Find & Obsolete TK807F Parts

The ABB AC500/S500 platform has an installed base spanning multiple industrial generations. A significant proportion of operational AC500 systems were commissioned between 2004 and 2015, placing their wiring accessories — including the TK807F supply cable — in the maintenance and lifecycle extension phase of procurement. ABB's standard spare parts availability for early TK807 variants is subject to lead times that can exceed 12–26 weeks through standard distribution channels, and certain sub-variants have been formally discontinued.

DriveKNMS maintains a dedicated inventory of TK807F and related AC500 S500 wiring accessories sourced through authorized surplus channels, factory-sealed new-old-stock (NOS), and tested-used stock. Our procurement team specializes in cross-referencing obsolete ABB part numbers against current equivalents and identifying compatible substitutes where direct replacements are unavailable. For plant maintenance teams operating under unplanned downtime scenarios, DriveKNMS provides expedited sourcing with same-day quotation response for in-stock items.

Quality Control for the TK807F Range

Supply cables for PLC I/O systems are passive components, but their failure modes — connector oxidation, insulation degradation, incorrect pin-out substitution — can cause intermittent I/O faults that are difficult to diagnose in live plant environments. DriveKNMS applies the following inspection protocol to all TK807F units prior to dispatch:

• Visual inspection of connector housings for mechanical damage, pin deformation, and locking tab integrity.
• Continuity testing across all conductors using calibrated low-resistance measurement equipment.
• Insulation resistance verification at 500 VDC to confirm dielectric integrity of cable sheathing.
• Pin-out verification against ABB documentation reference 1SAP180600R0001 to confirm correct conductor-to-connector mapping.
• Compatibility cross-check against target terminal unit model (TU505, TU516, TU531, etc.) to confirm mechanical and electrical fit.
• Packaging inspection to confirm factory seal status where applicable; NOS units are documented with source traceability records.