Month: July 2025

Product Series and Certification

Series Overview

ABB’s Tmax, Isomax, and Emax series molded case circuit breakers comply with UL 489 and CSA C22.2 standards, covering a current range of 15A to 2500A with a breaking capacity of up to 150kA (480V AC).

The product belongs to the IndustrialIT certification system and can be integrated into the ProtectIT suite, supporting collaborative work with distribution board components. Some models (such as T4 and T5) have e-plug communication interfaces.

Core features

Compact design: The depth of small-sized models is unified (such as 70mm for T1-T3), saving installation space.

Double insulation: Except for Isomax S8, electrical accessories can be installed on site to enhance safety and convenience.

Modular design: supports fixed, plug-in, and pull-out installations, with standardized accessories for easy maintenance.

Product Classification and Technical Parameters

1. Tmax series (15A-600A)

Model subdivision: T1-T5, covering 15A-600A, supporting thermal magnetic or electronic release devices (such as PR221DS, PR222DS/P).

Technical highlights:

T4/T5 has high breaking capacity and low let through energy limitation, reducing the impact of short-circuit current.

The electronic release supports overload (L), short circuit (S/I), and ground fault (G) protection, with adjustable parameters (such as I ₁=0.4-1 × In).

Application scenarios: power distribution, motor protection (MCP), isolation switch (MCS).

2. Isomax series (800A-2500A)

Model subdivision: S6-S8, covering 800A-2500A, using electronic release devices (PR211/P, PR212/P).

Technical highlights:

S6-S7 supports pull-out installation, while S8 is fixed with a breaking capacity of 125kA (480V AC).

Equipped with Modbus/Lon communication interface (PR212/D), it can be integrated into industrial networks.

Application scenarios: Medium to large power distribution systems, emergency power switching.

3. Motor Control and Protection (MCP)

Special models: T2-T3, S6-S8, equipped with adjustable magnetic release (6-12 × In) or electronic release (PR221DS-I).

Function: For three-phase asynchronous motors, it supports instantaneous protection against overload and short circuit, and adapts to different starting modes.

4. Isolation switch (MCS)

Model: Based on T1-T5 and S6-S8, without trip function, used for line isolation or switching.

Key technical parameters

Electrical performance

Rated voltage: AC 480V/600V, DC 500V, supports three-phase/single-phase systems.

Breaking capacity: For example, T2 has a breaking capacity of 65kA at 480V AC, and S8 can reach 100kA at 480V AC.

Release characteristics: thermal magnetic release (fixed/adjustable threshold), electronic release (LSIG four stage protection).

​Machinery and Environment

Operating lifespan: Mechanical lifespan 20000-25000 cycles, electrical lifespan 8000 cycles (415V AC).

Working temperature: -25 ℃ -70 ℃, storage temperature -40 ℃ -85 ℃, humidity ≤ 90% (non condensing).

Attachments and Extended Features

Communication and Monitoring

The electronic release supports Modbus RTU and LonTalk protocols and can be connected to SCADA systems.

Display unit (FDU) monitors current and fault records in real-time.

Safety and Control Accessories

Release devices: shunt release (SOR), undervoltage release (UVR), residual current release (RC221/222).

Operating mechanism: rotary handle (RHD/RHE), energy storage motor (MOE), mechanical interlock.

Signal and indication: auxiliary contact (AUX), alarm contact (SY), position contact (AUP).

Installation accessories

Terminal cover (IP40), phase partition, DIN rail mounting bracket.

Installation and Design Specifications

Environmental requirements

When the altitude is ≤ 2000m, the rated voltage needs to be reduced to 522V if it exceeds 6600ft.

The working temperature under forced air cooling is ≤ 70 ℃, and heat dissipation needs to be evaluated in high-temperature environments.

Spacing and Protection

Center distance between adjacent circuit breakers: T1-T3 ≥ 76mm, S6-S8 ≥ 210mm.

Protection level: The terminal cover provides IP40 protection against electric shock and foreign object intrusion.

Wiring and Debugging

Supports copper/aluminum cables, with terminal types including front wire (F), rear wire (R), and extension wire (EF/ES).

The debugging tool (PR010/T) can test the trip function and configure protection parameters.

Application and Industry Solutions

Distribution system: used for main distribution boards and distribution boxes, supporting selective protection coordination.

Industrial automation: integrated into PLC control system to achieve remote monitoring and fault alarm.

Architecture and Infrastructure: Emergency Power Switching (ATS010 Controller) for Hospitals and Data Centers.

Standards and Compliance

Compliant with UL 489, CSA C22.2, IEC 60947-2, passed EMC, tropical, and vibration tests.

Environmental certification: compliant with ISO 14001, recyclable materials, and lithium battery processing must comply with safety regulations.

Hardware architecture and features

1. Core processor and architecture

Processor: Adopting a 25MHz 32-bit MC68040 or MC68LC040 microprocessor, the former integrates on-chip instruction and data cache, floating-point processor, while the latter has no floating-point unit.

Bus structure: The local bus is a 32-bit synchronous bus that supports burst transmission and snooping mechanisms. The arbitration priority from high to low is: LAN (82596CA)>SCSI (53C710)>VMEbus>MPU.

2. Memory configuration

DRAM: Supports 1MB, 4MB, or 8MB optional, non interleaved (1MB/8MB) or interleaved (4MB) architecture, with parity check, can trigger interrupt or bus exception in case of error.

SRAM: 512KB with battery backup (powered by Dallas DS1210S), battery life can be maintained for 200 days in the event of a power outage at 40 ° C. The backup power source (VMEbus+5V or onboard battery) needs to be selected through J20 jump pin.

Non volatile storage:

8KB NVRAM (MK48T08) integrates real-time clock, supports BCD format display of hours, minutes, seconds, year, month, and day, and automatically processes leap years.

1MB Flash memory (1 Intel 28F008SA or 4 28F020), can be selected to boot from Flash or EPROM through J22 jump pin.

1 JEDEC standard 32 pin PLCC EPROM socket (supporting 4Mbit density).

3. Interface and Expansion Capability

VMEbus interface: implemented by VMEchip2 ASIC, supporting A24/A32 addresses, D8/D16/D32 data transfer, including DMA controller, interrupt processor, system controller and other functions.

Serial port:

The two ports are driven by the Zilog Z85230 controller and support EIA-232-D (DCE/LTE) or EIA-530 interfaces, configured through the SIM module (SIM05-SIM08).

The baud rate range is 110b/s to 38.4Kb/s, supporting synchronous (SDLC/HDLC) and asynchronous protocols.

Network and Storage:

Ethernet interface: Intel 82596CA controller, supports 32-bit DMA, and each card is assigned a unique MAC address ($08003E2XXXXX).

SCSI interface: NCR 53C710 controller, supporting 32-bit local bus burst DMA, ensuring correct termination at both ends of the bus.

Industry Pack (IP) interface: 4 single size or 2 dual size IP interfaces, controlled by IPIC ASIC, supporting external cable connections.

4. Physical and electrical specifications

Size:

Double height VME board, with a height of 9.187 inches without connectors and a height of 10.309 inches with connectors and front panel, and a thickness of 0.8 inches.

Power Supply:

+5V (± 5%), typical 3.5A, maximum 4.5A;+12Vdc (± 5%) and -12Vdc (± 5%), maximum 100mA.

environment

Working temperature: 0 ° C to 70 ° C (forced air cooling), storage temperature: -40 ° C to+85 ° C, relative humidity: 5% -90% (non condensing).

Installation and configuration process

1. Hardware preparation

Jumping needle configuration:

J1: System controller selection (default enabled, system controller when installing jump pin).

J10: SIM module selection for serial port B (EIA-232-D or EIA-530, DCE/LTE mode).

J20: SRAM backup power selection (VMEbus+5V or onboard battery).

J22: Universal readable jump pin, where GPO3 (pins 9-10) is used to select Flash/EPROM boot mapping.

Safety precautions:

Anti static operation, avoid touching integrated circuits; Disconnect all power sources before installation.

Lithium battery handling: Short circuit, disassembly, and heating are prohibited, and polarity should be noted when replacing.

2. Installation steps

Installation of IP module:

Four IP modules are installed on connectors such as J2/J3, J7/J8, and dual size IP requires adjacent interfaces.

External cables are led out through connectors such as J6 and J5, and users need to provide 50 pin cables themselves.

Installation of VME chassis:

The system controller needs to be installed in slot 1 of the chassis, and non controllers can be installed in any double height slot.

Connect the P1 and P2 connectors to ensure they are securely fastened; Remove the IACK and BG jump pins from the corresponding slots on the chassis backplane.

Transition module connection:

Install MVME712 series transition modules (such as MVME712M, MVME712A) and connect serial ports, SCSI, and Ethernet interfaces through a P2 adapter board.

3. Cable and interface connection

Serial port:

Port 1 (CONSOLE) is connected through a DB-25 connector and defaults to asynchronous mode; Port 2 is configured through the SIM module and transition module.

SCSI and Ethernet:

The SCSI interface is connected through a P2 connector and requires the installation of a terminal resistor; The Ethernet interface is led out through the DB15 connector of the MVME712X transition module.

Debugging Tools and Firmware (162Bug)

1. Firmware Overview

Function: Integrated into Flash/PROM, providing functions such as memory debugging, program loading, hardware diagnostics, etc., supporting system self startup and network startup.

Startup mode:

Board Mode: default startup, displays the “162 Bug>” prompt, supports manual command operation.

System Mode: configured through ENV commands, supports automatic testing and system booting.

2. Core functions and commands

Memory operation:

MD: Displays memory content, supports byte/word/long word formats, and can be disassembled (DI option).

MM: Modify memory data and support direct writing of assembly instructions.

Program execution:

GO: Execute the program from the specified address and support breakpoint setting (BR command).

GT: Execute to a temporary breakpoint for single step tracking.

Disk and Network:

BO/BH: Start the operating system/load programs from the disk and pause.

NBO/NBH: Start the system through network (TFTP/BOOTP) and support IP configuration.

Diagnostic tool:

IOC/IOP: Directly operate the disk controller to test hardware functionality.

CNFG/ENV: Configure onboard information blocks (BIBs) and environment parameters (such as startup latency, memory mapping).

3. Automatic start mechanism

Autoboot: After powering on, it scans disk devices and starts in order of LUNs, which can be interrupted by pressing the<BREAK>key.

Network Boot: Obtain IP through RARP/BOOTP, load boot files through TFTP, and support diskless system boot.

ROMboot: User defined boot code that meets memory mapping and checksum requirements.

Safety and Compliance Standards

Electromagnetic Compatibility (EMC)

The device complies with FCC Part 15 Subpart J Class A standards and can avoid interference when used in commercial environments; If there is interference in the residential environment, users need to take measures on their own.

Safety operation standards

Grounding: Use a three core power cord to ensure that the chassis is grounded (connect the green wire to a safe ground).

Prohibited environment: Do not operate in flammable gas environments.

Maintenance restriction: Only authorized personnel are allowed to open the chassis, operate after power off and discharging.

Warning signs

SYSFAIL * signal: If a memory verification error, low battery voltage, or other fault is detected after power on, the VMEbus SYSFAIL * signal will be asserted.

LED indicator lights: FAIL (red) indicates hardware failure, RUN (green) indicates local bus activity, SCON (green) indicates system controller status.

Summarize

The MVME162 embedded controller, as a classic VMEbus architecture product from Motorola, integrates high-performance processors, rich interfaces, and reliable memory systems, making it suitable for industrial control, embedded computing, and other scenarios. The document provides users with full process support from hardware deployment to system startup through detailed hardware instructions, installation procedures, and debugging tool guides, while emphasizing security standards and compatibility design to ensure stable device operation.

Product Overview and Positioning

TU810/TU810V1 is a 16 channel 50V compact module terminal unit (MTU) designed specifically for ABB System 800xA automation systems, and is a key component of the S800 I/O system. As a passive interface unit, its core function is to achieve electrical connection between field wiring and I/O modules, while carrying the transmission and distribution of Module Bus signals. This MTU adopts a modular design, supports mechanical keying configuration, ensures compatibility with different types of I/O modules, and is suitable for signal access and system expansion in industrial automation scenarios.

Core functions and technical features

Module Bus Management

As the physical carrier of the Modulus Bus, TU810V1 is responsible for distributing bus signals to connected I/O modules and the next level MTU, forming a chain topology structure.

By shifting the output position signal to generate I/O module addresses, automatic addressing is achieved, simplifying the system configuration process.

Mechanical key control configuration system

Equipped with two sets of six position mechanical keys, compatible with the full range of S800 I/O modules such as AI810, AO810, DI810, DO810, etc. through different combinations (a total of 36 configurations).

Keying is only for mechanical positioning and does not affect electrical functions, but it can effectively prevent module misconnection and improve installation reliability.

Signal and power connection

16 channel on-site signal interface: supports standard industrial signals (such as 4-20mA, 0-10V, etc.), with a maximum current of 2A per channel.

Process power connection: Provide 2 × 2 or 5 × 2 power terminals (0V common terminal), supporting a maximum current of 5A, to meet the power supply requirements of sensors and actuators.

Wiring specifications: Solid wire 0.2-4mm ², stranded wire 0.2-2.5mm ² (24-12 AWG), compatible with mainstream industrial cables.

Installation and Protection Design

DIN rail installation: supports horizontal (up to 55 ℃) and vertical (up to 40 ℃) installation, with grounding locking device to ensure electromagnetic compatibility.

Compact structure: Size 170 × 64 × 64mm (height × width × depth), weight only 0.17kg, saving control cabinet space.

Protection level: IP20 (preventing solid foreign objects from entering), suitable for indoor industrial environments, pollution level 2 (IEC 60664-1).

Electrical and Environmental Parameters

Electrical performance

Dielectric strength: 500V AC test to ensure insulation safety between channels.

Overvoltage category: Compliant with IEC 60664-1 standard, suitable for industrial grade power systems.

EMC compatibility: Following EN 61000-6-4 (emission standard) and EN 61000-6-2 (immunity standard), it has strong electromagnetic interference resistance.

Environmental adaptability

Temperature range: working temperature 0-55 ℃, storage temperature -40-70 ℃, supports wide temperature operation.

Humidity conditions: 5% -95% without condensation, meeting the requirements of humid environments (IEC 61131-2).

Corrosive atmosphere: Complies with ISA-S71.04 G3 grade and is suitable for moderately corrosive industrial scenarios such as chemical and metallurgical industries.

Certification and Compliance

Safety certifications: CE, UL 508, cULus (Hazardous Area Class 1, Division 2/Zone 2), ATEX Zone 2, supporting applications in explosion-proof areas.

Classification society certification: ABS, BV, DNV-GL, LR, RS, CCS, applicable to ship automation systems.

Environmental standards: RoHS (EN 50581:2012) and compliance with the WEEE directive, supporting green manufacturing.

List of compatible I/O modules

Analog inputs (AI): AI810, AI815, AI820, AI830, AI830A, AI835, AI835A, AI845

Analog Output (AO): AO810, AO810V2, AO815, AO820, AO845, AO845A

Digital Input (DI): DI810, DI811, DI814, DI830, DI831, DI840, DI880, DI885

Digital Output (DO): DO810, DO814, DO815, DO840, DO880

Pulse/Count Input (DP): DP820, DP840

Application scenarios and system integration

Typical application areas

Process automation: signal acquisition and control in the chemical, petroleum, and power industries, such as temperature, pressure, and flow sensor integration.

Mechanical manufacturing: digital input/output control of machine tools and production lines (such as solenoid valves, encoder signal processing).

Ship and Maritime: Engine room monitoring, deck equipment control, meeting the requirements of marine environmental certification.

System topology

Chain extension: Multiple MTUs are connected in series through a Modulus Bus, supporting maximum I/O point expansion and suitable for large control systems.

Redundant configuration: Although MTU is designed as a single channel, it can be combined with redundant I/O modules to improve system reliability.

Installation and wiring precautions

Grounding requirement: Reliable grounding through DIN rail latch to reduce electromagnetic interference.

Cable management: It is recommended to use shielded cables and lay signal and power cables separately to avoid crosstalk.

Product Overview

Positioning: SPAJ 140 C is a combination overcurrent and ground fault relay used for selective short-circuit and ground fault protection of radial feeders in solid grounding, resistance grounding, or impedance grounding power systems. It can also be used in other application scenarios that require single-phase, two-phase, or three-phase overcurrent protection and non directional ground fault protection.

Core function: Integrated phase overcurrent unit and ground fault unit, with circuit breaker fault protection function, providing multiple output relay configurations and powerful data communication capabilities.

Core functions

Protection function:

Phase overcurrent protection: includes low setting stage I>(timed or inverse time characteristic) and high setting stage I>>(instantaneous or timed function).

Ground fault protection: Low setting stage I0>(timed or inverse time characteristic) and high setting stage I0>>(timed function).

Other protections: transformer surge detection, thermal overload protection, phase to phase circuit breaker protection, negative sequence overcurrent protection, circuit breaker fault protection.

Control and signal functions:

External control inputs can be used to block protection stages, reset latch output relays, or remotely control relay settings.

Provide two heavy-duty and four light-duty output relays, which can be configured through switch group functionality.

Measurement and recording:

Continuously measure phase current and neutral current, and display the highest load phase current and ground current by default.

The event log stores 100 timestamp events and records the simulated values of the last five trip events.

Self supervision and testing:

Built in self-monitoring system, monitoring hardware and software status, triggering alarms and blocking protection functions when faults are detected.

Support built-in testing mode to test HMI and binary output.

Technical characteristics

Hardware parameters:

The rated current is 1A or 5A, and the thermal withstand capacity is continuous 4A/20A and 100A/500A per second, respectively.

Power supply voltage range: SPTU 240 R1 is 80-265V DC/AC, SPTU 48 R1 is 18-80V DC, with a power consumption of approximately 4-6W.

Protection features:

The low setting stage of overcurrent and ground fault protection can select time limit (DT) and inverse time limit (IDMT) characteristics, supporting multiple standards and special curves.

The circuit breaker fault protection generates a trip signal after a set time (0.1-1 seconds) following the main trip signal.

Communication and Interface:

Built in serial port, supporting MODBUS RTU or IEC 60870-5-103 protocol, connected via fiber optic SPA bus.

Four binary inputs and six output contacts, the output contacts can be configured for different functions.

Application scenarios

Suitable for short-circuit, overcurrent, and grounding fault protection of incoming and outgoing feeders, overhead lines, and cable feeders in medium voltage distribution stations, as well as main protection of distribution transformers.

Different application configurations (B/C/D) provide different combinations of functions to meet different protection requirements.

Operation and Settings

Human computer interaction: The local HMI includes an alphanumeric LCD display screen, LED indicator lights, and navigation keys, supporting multiple languages.

Setting method: Use a portable PC and software to set parameters through the front panel buttons or serial port, supporting switching between two sets of parameters: main settings and second settings.

Switch group configuration: Configure relay functions and output signal routing through software switch groups SGF, SGB, and SGR.

Technical parameters

Size and Installation: Adopting a crimping panel installation, the size is about 130 × 160 × 151.5mm, the weight is about 3.5kg, the protection level is IP54 for the front panel, and IP20 for the back terminal.

Environmental conditions: working temperature -10 ℃~+55 ℃, storage temperature -40 ℃~+70 ℃, relative humidity<95% (no condensation), altitude up to 2000 meters.

Electromagnetic compatibility: Complies with standards such as IEC 60255 and has passed tests such as high-frequency pulses, electrostatic discharge, and rapid transients.

Product positioning and core values

AC 800PEC is a high-performance industrial control system launched by ABB, developed specifically to meet model-based design and high-speed control algorithm requirements. Its core advantage lies in integrating traditional separated high-speed control (such as power electronics applications) and low-speed process control (PLC tasks) into a single processor unit, achieving full range cycle time coverage from 100 microseconds to several seconds. This system is based on ABB’s ControlIT automation technology, combined with MATLAB ®/ Simulink ®  Model development tools significantly shorten the engineering cycle from simulation to implementation, suitable for scenarios such as traction, power generation, and industrial processing that require high real-time and reliability.

Hardware architecture and performance parameters

Processing Core and Architecture

Collaborative design of CPU and FPGA: The CPU is responsible for floating-point operations and complex logic, while the FPGA handles ultra high speed tasks (such as 25 nanosecond logic), forming a three-level performance hierarchy:

Ultra fast layer: 25 nanosecond task (VHDL programming, firmware module implementation);

Fast layer: 100 microsecond loop (MATLAB) ®/ Simulink ®  Control algorithm);

Slow layer: tasks lasting over 1 millisecond (programming in IEC 61131-3 language).

I/O system:

Fast I/O: Fiber optic connection, transmission time<10 microseconds (internal) to 25 microseconds (external), anti electromagnetic interference, no need to isolate transmitter;

Slow I/O: Compatible with ABB S800 module and supports millisecond level response.

Hardware scalability

Three architectural patterns:

Compact: Single processor integrated I/O, suitable for small devices or distributed subsystems;

Standard type: independent processor+fast I/O, suitable for central control scenarios;

Modularization: Multi processor+intelligent I/O, supporting redundant configuration of large systems.

Environmental adaptability:

Working temperature: -40 ℃ to+70 ℃ (traction field);

Anti vibration: Complies with traction industry standards and is designed with no moving parts.

Software Ecology and Programming System

Third level software architecture

Level 1: Systems Engineering

Tool: ABB Control Builder (Compact/Professional version);

Language: All 5 IEC 61131-3 languages (LD, FBD, ST, etc.);

Application: Non high speed logic (parameter configuration, system adaptation), can be integrated into 800xA automation systems.

Level 2: Control Algorithm Development

Tool: MATLAB ®/ Simulink ® +  Real-Time Workshop ®；

Process: Model simulation → Automatic generation of C code → One click download to controller;

Application: Core algorithms such as closed-loop control, protection logic, and state machines.

Level 3: Ultra High Speed Logic

Tools: VHDL+FPGA development framework;

Function: Communication protocol (such as Powerlink), pulse modulation, hardware level protection, firmware level packaging cannot be modified.

Model driven development process

Traditional vs Modern Workflow:

Traditional: specification definition → code handwriting → debugging (error prone, long cycle);

AC 800PEC：Simulink ®  Model → Automatic code generation → Real time debugging (online parameter optimization, direct deployment via Ethernet).

Communication and integration capabilities

Native protocol support

Industrial bus: Profibus DPV1 (master station), Modbus RTU/TCP, IEC 61850 (power system) CANopen；

ABB exclusive: Powerlink, Drivebus (DDCS), Modulabus (S800 fiber optic).

Expansion

Through the CEX module: Drivebus slave station ControlNet、DeviceNet；

Supports RS-232/422 serial port through Anybus modules such as Profinet, EtherCAT, Ethernet/IP, etc.

System integration

Deeply compatible with ABB 800xA automation platform, achieving unified monitoring from on-site equipment to factory level, supporting firewall and security authentication to prevent unauthorized access.

Typical application scenarios

Traction field (railway/rail transit)

Challenge: Wide temperature range, strong vibration, limited space;

Scheme: compact hardware+anti vibration design, stable operation from -40 ℃ to+70 ℃, integrated I/O and processor in the same module, meeting the space requirements of on-board equipment.

Power generation and excitation control

Requirement: High reliability, redundant and fault-tolerant;

Solution: Modular architecture+hot standby redundancy, automatically switches to the standby unit when the main controller fails, ensuring continuous operation of the generator excitation system, suitable for key equipment in power plants.

Industrial process control (such as cold rolling mill)

Challenge: Thickness control accuracy (MIMO multiple input multiple output system);

Solution: MATLAB ®/ Simulink ®  Develop model predictive control algorithm, combined with C code acceleration, to improve thickness deviation by 50%, surpassing traditional control schemes.

Engineering benefits and customer value

Performance improvement:

Control accuracy: The thickness deviation of the cold rolling mill is reduced by 50%;

Response speed: 100 microsecond cycle time, suitable for high-frequency switching requirements of power electronic devices.

Cost optimization:

Development cycle: The model automatically generates code, reducing manual programming workload by 50%;

Hardware investment: Integrating multitasking with a single processor to reduce the separate procurement cost of PLC and high-speed controller.

Sustainability:

Energy consumption: Efficient algorithms reduce device operating power consumption;

Lifecycle: Industrial grade hardware design, supports long-term upgrades, and protects user investments.

Service and Support System

Tool chain: AC 800PEC specialized tools cover the entire engineering cycle (design, commissioning, maintenance);

Training system: Provide courses such as model development and system integration to enhance user team skills;

Global service: 100+country offices, 24-hour technical support, combined with local experience and global resources.

Product positioning and overview

Product positioning 

REF601: Dedicated feeder protection and control relay, integrating protection, monitoring, and circuit breaker control functions, suitable for incoming and outgoing feeder lines in medium voltage distribution networks.

REJ601: Overcurrent protection relay, without circuit breaker control function, focusing on overcurrent and ground fault protection.

Series affiliation: Belongs to ABB Relion ®  The 605 series is designed based on professional knowledge in the field of digital technology and protection, and supports pre configuration to simplify debugging.

Core advantages

Compact design, suitable for the renovation of switchgear with limited space, using crimping installation without the need for additional accessories.

Provide three application configurations (B/C/D) to meet different protection requirements and support ANSI/IEC standards.

Core Function Analysis

1. Protection function (REF601/REJ601 universal)

Overcurrent protection:

Three stage non directional overcurrent: low setting stage (51P/3I>), high setting stage (50P-1/3I>>), instantaneous stage (50P-2/3I>>), supports IDMT (inverse time limit) and DT (definite time limit) characteristics, compatible with IEC 60255-3 and ANSI C37.112 standard curves (such as Normal Inverse, Very Inverse).

Two stage grounding fault protection: low setting stage (51N/Io>), high setting stage (50N/Io>>), which can calculate the grounding current through external zero sequence CT or internal phase current.

Auxiliary protection:

Transformer surge detection (68/3I2f>) to prevent accidental tripping when the transformer is closed.

Thermal overload protection (49/3Ith>), suitable for feeders, cables, and transformers, supports thermal aging simulation.

Phase to phase open circuit protection (46PD/I2/I1>), negative sequence overcurrent protection (46/I2>), identify asymmetric faults.

Circuit breaker fault protection (50BF/50NBF), activate backup protection when detecting circuit breaker refusal to move.

2. Control function (REF601 only)

Circuit breaker control: Switching is achieved through local HMI buttons or communication interfaces (MODBUS/103 protocol), equipped with two dedicated output contacts.

Automatic reclosing: Supports 4 reclosing cycles, configurable dead time, pulse time, and lockout logic, suitable for overhead line fault recovery.

3. Monitoring and recording

Real time measurement: Continuously monitor three-phase current, grounding current, optional negative sequence current, thermal level, and operation counting.

Event log: Stores 100 events with a 1ms timestamp (such as protection actions, trip circuit status), supports local/remote queries.

Fault recording: Record the analog data (three-phase current+ground current) of the last 5 tripping events for fault analysis.

4. Self supervision and safety

Self diagnosis: Real time monitoring of hardware (such as CPU, memory) and software status, blocking protection functions and alerting in case of faults.

Trip Circuit Monitoring (TCM): detects open circuit and loss of control voltage in the trip circuit, and supports monitoring of the opening and closing status of the circuit breaker.

Access control: three-level user permissions (operator/engineer/administrator), supporting alphanumeric password or key combination authentication.

Application scenarios and configurations

Typical applications

Medium voltage distribution station: short circuit, overcurrent, and grounding fault protection for incoming and outgoing feeder lines.

Distribution transformer: utilizing surge detection function as the main protection.

Overhead lines and cables: improve power supply reliability through automatic reclosing (REF601).

Configuration differences

Configuration B: Basic function, providing non directional overcurrent+ground fault protection, with ground current calculated from phase current.

Configuration C: Add thermal overload, phase to phase circuit breaker, and circuit breaker fault protection on the basis of B.

Configuration D (REF601 only): Add negative sequence protection and quadruple automatic reclosing on the basis of C, suitable for overhead line feeders.

Technical Parameter

1. Electrical parameters

Power supply: AC/DC 24-240V, fluctuation range AC 85-110%/DC 70-120%, static power consumption<5VA.

Current input:

Rated current: 1A or 5A (optional), continuous withstand current 4A/20A, 1-second withstand current 100A/500A.

Input impedance:<100m Ω (1A)/<20m Ω (5A).

2. Machinery and Environment

Dimensions: 130mm (width) x 160mm (height) x 151.5mm (depth), weight 1.43kg.

Environmental adaptation:

Working temperature: -25 ℃~+55 ℃, short-term storage -40 ℃~+85 ℃.

Humidity:<93% without condensation, altitude ≤ 2000 meters.

3. Electromagnetic compatibility (EMC)

Anti interference: Tested through electrostatic discharge (6kV contact/8kV air), radiated electromagnetic field (10V/m, 80MHz-2.7GHz), fast transient (4kV), etc.

Emission limit: Complies with EN 55011 standard, with conducted radiation<66dB (μ V/m) and radiated radiation<47dB (μ V/m).

4. Insulation and Protection

Dielectric strength: 2kV/1min, impulse voltage 5kV (1.2/50 μ s), insulation resistance>100M Ω.

Protection level: front panel IP54, back terminal IP20.

​Interface and Communication

Input/output

Analog input: 4-channel current input (3-phase+grounded), supporting 1A/5A CT.

Binary input: 4 channels, configurable for circuit breaker position, trip command, etc.

Output contacts: 6 channels (2 power outputs+4 signal outputs), with a maximum switching capacity of 240V/8A.

communication interface

Optional MODBUS RTU or IEC 60870-5-103 protocol, RS485 two-wire connection, supports remote monitoring and parameter configuration.

Ordering and Accessories

Order coding rules

Example: REF601 A E4 46 B D 1 B H, including relay type, standard (ANSI/IEC), current input specifications, communication protocol, application configuration, and other information.

Accessory

Communication card: CIM601BNNNNBANXG, used to add MODBUS or 103 protocol interfaces.

Summarize

ABB REF601/REJ601 relays provide a solution for medium voltage distribution systems that integrates protection, control, and monitoring through modular design and flexible configuration. Its core advantages lie in:

Comprehensive protection: covering multiple protection functions such as overcurrent, ground fault, thermal overload, etc., supporting custom characteristic curves.

Strong adaptability: Three application configurations are suitable for different scenarios, and the compact design meets space constraints.

High reliability: Self supervision and trip circuit monitoring enhance system safety, while EMC and environmental testing ensure industrial grade durability.

Ease of operation: Local HMI and hierarchical permission management simplify on-site debugging, and communication interface supports remote operation and maintenance.

Suitable for urban distribution networks, industrial power systems, and other scenarios, especially for situations that require efficient fault protection and power supply reliability.

Document Overview and Core Positioning

Document property

This manual is the service manual for the RPH3 “Point on Wave (PoW)” controller, which is used to guide the synchronous switching operation of high-voltage switchgear and support equipment understanding, installation, use, and maintenance.

Copyright belongs to GE Grid Solutions. The content is informative and can be adjusted according to technical and commercial needs. Unauthorized reproduction and disclosure are prohibited.

Reference architecture

GE internal documents: such as D1621EN (User Manual), D1622EN (RPH Manager Software Manual), etc.

International standard: Following IEC 62271-302 (Non synchronous pole operation of high-voltage switchgear).

Industry Report: Cited from CIGR É 262-264 publication (HVAC Switchgear Control Switching Guide).

Safety and Operation Instructions

Static Electricity and Electrical Safety

Electrostatic discharge (ESD) may damage equipment and should comply with anti-static standards such as EN 61340-5-1.

Power off before operation, confirm that the power supply voltage is compatible (AC 100-240V or DC 48-353V), only qualified engineers can operate.

Storage and installation requirements

Store in a dust-free and dry environment at -40 ℃~+70 ℃, with moisture-proof bags retained; Installed in the control room or relay room, ensuring good grounding, away from vibration sources, supporting 19 inch rack or wall mounted installation.

Principle of PoW Switching Technology

Random switching vs synchronous switching

Random switching: When the coils are powered on simultaneously, it is easy to generate surge current and overvoltage, which can cause equipment aging or protection misoperation.

PoW switching: By delaying the control of coil energization time, the high-voltage contacts are made to contact at the target point of the voltage waveform (such as zero crossing or peak), reducing transient phenomena. For example:

Inductive load (transformer) closing selects peak voltage to reduce excitation inrush current;

Capacitive load (capacitor) closing selects voltage zero crossing to reduce charging current surge.

Key parameters and terminology

Pre arming Time: The current conduction time before the mechanical contact of the contacts during closing, influenced by the dielectric strength decay rate (RDDS).

Operating Time: The time it takes for the coil to be powered on until the contacts fully move, and it is necessary to compensate for the effects of environmental temperature, hydraulic pressure, and other factors.

Adaptive Control: Based on historical operational data, adjust control timing and compensate for unpredictable factors such as equipment aging.

RPH3 Hardware and Functional Architecture

Module composition

M1: Power module, providing internal DC power supply.

M2: Central processing and communication module, integrated with DSP and Linux system, supporting Ethernet and fiber optic communication.

M3: Analog acquisition module, sampling reference voltage, current, temperature, hydraulic pressure and other signals.

M4: Signal and coil drive module, processing switch commands and relay outputs.

M5: Front panel management module, controls LED indicator lights and serial communication.

Core functional modules

Reference voltage sampling: Obtain the grid voltage through VT as a timing reference, supporting L1/L2/L3 phase selection.

Neutral point mode detection: supports hardware jumpers (M4-J5) or software settings to distinguish between grounded, isolated, or unknown modes.

Coil driver: Supports common mode/differential mode wiring, outputs 80ms adjustable pulses, and drives the opening and closing coils of switch devices.

Operation time measurement: Detect contact action through auxiliary contacts or current transformers (CT) with an accuracy of ± 0.1ms.

Compensation mechanism and adaptive control

Compensation factors for operation time

Environmental temperature: Low temperature will prolong operation time. Real time compensation can be achieved through a temperature sensor (4-20mA input), and the compensation meter can be configured through Web MMI.

Control voltage: Voltage fluctuations affect the rate of rise of coil current. The compensation value is calculated using the formula Δ t voltage=(U meas U rate − 1) ⋅ kU ⋅ t OP_rated, where kU is the compensation coefficient (to be measured).

Hydraulic pressure: For hydraulic drive mechanisms, real-time sampling is carried out through pressure sensors, and compensation is made according to Δ t pressure=(P meas P rate − 1) ⋅ kP ⋅ t OP_rated.

Idle time: Devices that have not been operated for a long time will slow down, compensated by the exponential function Δ t idle=A ⋅ (1 − e − BT idle), where A and B are empirical parameters.

Adaptive control is based on historical operational data and utilizes Δt adapt=K⋅(t measured −t commissioning −Δt compensations)+(1−K)⋅Δt adapt_prev  Adjust the prediction time series, with K as the weight factor (default 0.3).

Alarm and Data Management

Alarm Type

System alarm: such as abnormal power supply, hardware failure, calibration failure, etc., triggering the red LED “3” on the front panel.

Application alarm: If the reference voltage exceeds the limit, the operation time is abnormal, the compensation value exceeds the limit, etc., the LED “4” will be triggered.

Relay output: 5 relays (1 monostable+4 bistable), which can be configured with alarm correlation logic through Web MMI.

Data recording and communication

Real time data: View parameters such as voltage, current, temperature, etc. through Web MMI, with a refresh rate of 3 seconds or 20 seconds.

Switching record: Stores the last 1025 operation data (“*. arch” file), supports downloading waveforms and event logs through RPH Manager software.

Network interface: Supports IP network (default IP 192.168.5.2), compatible with IEC 61850-9-2 communication protocol.

Application scenarios and switching strategies

Typical load switching scheme

Transformer/Three core Reactor:

Closing: Select the peak voltage (90 ° electrical angle) for the grounding neutral point, and select 0 ° or 180 ° for the isolation neutral point.

Trip: Select the current zero crossing point (corresponding to the peak voltage) to reduce overvoltage.

Single core reactor: The closing target point is the same as the transformer, and the tripping strategy is consistent.

capacitor:

Closing: Select voltage zero crossing (0 °) for the grounding neutral point and phase voltage zero crossing for the isolation neutral point.

Trip: Select the zero crossing point of the current to avoid heavy impact.

Transmission line:

Inductive VT: select voltage zero crossing for closing;

Capacitive VT: It is necessary to evaluate the residual charge in the circuit and select the peak voltage for closing.

Inductive load with NGR: Select the neutral point mode based on the inductance ratio r=LL N, and use a custom switching program when r ≥ 0.3.

Switch program configuration

Built in preset programs (transformers, reactors, capacitors), supporting user-defined modes (User Mode), can adjust the angle offset of each phase.

Technical parameters and specifications

Physical characteristics: 19 inch 4U rack, dimensions 483 × 177 × 452mm, protection level IP20.

Electrical parameters:

Power supply: AC 100-240V/50-60Hz or DC 48-353V, power consumption<20W;

Coil driving voltage: DC 33-300V, maximum current 30A (300ms).

Measurement accuracy: Voltage/current sampling error ≤ 1%, operation time measurement error ≤ ± 0.1ms.

Environmental adaptability: Operating temperature -25 ℃~+50 ℃, storage temperature -40 ℃~+70 ℃, compliant with RoHS and EMC standards (such as IEC 61000-4-2/3/5).

The medium voltage V-Contact VSC contactors are apparatus suitable for operating in alternating current and are normally used to control users requiring a high number of hourly operations.

The V-Contact VSC contactor introduces the drive with permanent magnets, already widely used,experimented and appreciated in medium voltage circuit-breakers, into the worldwide panorama of medium voltage contactors.

The experience acquired by ABB in the field of medium voltage circuit-breakers fitted with drives with “MABS” permanent magnets, has made it possible to develop an optimised version of the actuator (bistable MAC drive) for medium voltage contactors.

The drive with permanent magnets is activated by means of an electronic multi-voltage feeder. The feeders differ according to the integrated functions and to the auxiliary power supply voltage.

Three bands of power supply are available with which all the voltage values required by the major international Standards can be covered.

Each feeder is able to take any voltage value within its own operating band.

All the contactors mentioned above are available,on request, in one of the two following versions.

SCO(Single Command Operated): closing takes place by supplying auxiliary power to the special input of the multi-voltage feeder. On the other hand, opening takes place when the auxiliary power is either voluntarily cut off (by means of a command) or involuntarily (for lack of auxiliary

power in the installation).

DCO (Double Command Operated): closing takes place by supplying the input of the closing command of the apparatus in an impulsive way.

On the other hand, opening takes place when the input of the opening command of the contactor is supplied in an impulsive way.

Fields of application

The V-Contact VSC contactors are suitable for controlling electrical apparatus in industry, in the service sector, in the marine sector, etc.

Thanks to the breaking technique with vacuum interrupters, they can operate in particularly difficult environments.

They are suitable for control and protection of motors, transformers, power factor correction banks, switching systems, etc. Fitted with suitable fuses, they can be used in circuits with fault levels up to 1000 MVA (VSC7 – VSC12)

Compliance with Standards

V-Contact VSC contactors comply with the Stand ards of the major industrialised countries and in particular with the EC 60470 (2000) Standards.

Approvals

Approval by the DNV, RINA and LL.RR shipping registers is foreseen.

Operating characteristics

• Ambient temperature:  – 5 °C … + 40 °C

• Relative humidity: < 95 %  (without condensa tion)

• Altitude: < 1000 m s.l.m.

Main technical characteristics

• Chopping current value  ≤  0.5 A

• Maintenance-free

• Suitable for installation in prefabricated substations and switchgear both of the card (slim line) and traditional type

• High number of operations

• Direct checking of contact wear

• Long electrical and mechanical life

• Remote control

• Multi-voltage feeder

• Bistable drive of the type with permanent magnets

• Behaviour on power cut adjustable by the customer (instantaneous or delayed opening) in the SCO versions and, should the undervolt age accessory be required, DCO.

Interruption principle

IThe main contacts operate inside the vacuum interrupters (the level of vacuum is extremely high: 13 x 10-5Pa).

On opening, there is rapid separation of the fixed and moving contacts in each contactor interrupter.

Overheating of the contacts, gener ated at the moment they separate,causes formation of metallic vapours which allow the electric arc to be sustained up to the first passage through zero current.

On passage of zero current, cooling of the metallic vapours allows recovery of high dielectric resist ance able to withstand high values of the return voltage.

For motor switching, the value of the chopped current is less than 0.5 A with extremely limited overvoltages.

“MAC” magnetic drive

ABB has implemented this technology in the field of contactors on the basis of experience gained in the field of circuit-breakers with magnetic drive.

The magnetic drive adapts perfectly to this type of apparatus thanks to its precise and linear travel.

The drive, which is of bistable type, is fitted with an opening and a closing coil.

The two coils – individually energised – allow the drive mobile armature to be moved from one of the two stable positions to the other.

The drive shaft is solid with the mobile armature and held in position in a field generated by two permanent magnets (fig. A).

Energising the coil opposite to the magnetic latching position (fig. A) of the core, the magnetic field is generated (fig. B), which attracts and moves the mobile armature into the opposite position (fig. C).

Every opening and closing operation creates a magnetic field concordant with the one generated by the permanent magnets, with the advantage of keeping the intensity of the field itself constant during service, regardless of the number of opera tions carried out.

The energy needed for operation is not supplied directly by the auxiliary power supply, but is always “stored” in the capacitor which acts as an energy accumulator, and therefore operation always takes place with constant speeds and times, independ ently of the divergence of the power supply voltage from the rated value.

The auxiliary power supply has the only aim of keeping the capacitor charged.Consumption is therefore minimal. 

The power required is less than 5 W. In order to re-instate the rated power value in the capacitor after an opera tion, there is an inrush of 15 W for a duration of a few tens of milliseconds.

For the reasons indicated above, both for the DCO and for the SCO version it is necessary to supply the auxiliary circuits which recharge the capacitor with a continuous auxiliary power supply of 5W (this value can reach 15W for a few milliseconds immediately following each operation).

Careful selection of the components and a precise design make the electronic multi-voltage feeder extremely reliable, unaffected by electromagnetic interference generated by the surrounding environ ment and free of any emissions which may affect other apparatus placed in the vicinity.

These characteristics have made it possible for the V-Contact VSC contactors to pass the electromag netic compatibility tests (EMC) and obtain the CE mark.

​Interfacing shafts

These can be used to interface the apparatus with the kinematics of the switchgear to make interlocks and/or signals.

The interfacing shafts are available in two different lengths (A = 22 mm and 70 mm) and can be mounted on one or both sides of the contactor (as indicated in the following table)

Operation counter

Mechanical operation counter for fixed versions, electric operation counter for withdrawable versions.

This is a device which counts the contactor closing cycles 3 Undervoltage function (only available for DCO)

First of its type, the V-Contact VSC contactor is fitted with an undervoltage function with selectable delays of 0; 0,5; 1; 2; 3; 4; 5 s.

This accessory must be specified at the time of order because it cannot be mounted at a later stage.

Extended connections (terminals)

These allow the centre distance between terminals to be taken from 65 mm to 92 mm.

This accessory must be specified at the time of order because it cannot be mounted at a later stage.

Adapter for application of fuses

The kit includes all the accessories needed to adapt and mount three fuses(according to DIN Standards with dimension e less than 442 mm; according to BS Standards with dimension L less than 553 mm).

The kit can be installed directly onto the fuseholder supports. 

The fuses must have dimensions and striker of average type according to DIN 43625 and BS 2692 (1975) Standards. 

The electrical characteristics must conform to the IEC 282-1 (1974) Standards.

To select the fuses, see “Conditions of use according to the load” – chapter 3.

The adaptation kits are available in the following types:

3A For fuses according to DIN Standards with distance e = 192 mm

3B For fuses according to DIN Standards with distance e = 292 mm

3C For fuses according to BS Standards (2 x 8 x L = 235 mm)

3D For fuses according to BS Standards (4 x 10 x L = 305 mm)

3E For fuses according to BS Standards (4 x 10 x L = 410 mm)

3F For fuses according to BS Standards with distance L = 454 mm.

Connections alternative to the fuses

The kit includes three flat copper busbars and fixing screws to be installed when the fuses are not needed.

The kit can be installed directly onto the fuseholder supports

Position contacts for connected/isolated position in the truck

These signal the position of the truck in the enclosure/PowerCube module.

The kit includes a set of 10 auxiliary contacts. 

This accessory must always be requested for contacts to be used in UniGear type ZS1 switchgear if the same application is not already present on the fixed part.

Isolation lock

Isolation lock for UniGear type ZS1 switchgear and PowerCube modules.

It prevents the apparatus from being racked-in if the unit door is open.

This lock only works if the door of the switchgear/enclosure is also fitted with the corresponding lock.

Locking magnet in the truck

This only allows the withdrawable contactor to be racket into/out of the enclo sure with the electromagnet energised and the contactor open

The table below shows the power supply voltages available.

10Lock for different rated currents (only withdrawable versions)

This prevents insertion of the plug-socket and therefore apparatus closing, in a panel provided for a circuit-breaker.

This lock, which is compulsory for UniGear switchgear, requires the same lock provided on the enclosure / switchgear

Product model: UNS 0884a, V1

Corresponding ABB number: 3BHE004385R0001

Current measurement range: 2000A

Origin: Sweden. As a well-known brand, ABB strictly controls its product technology and quality. This current sensor inherits ABB’s high-quality genes.

Certification status: With CO.CQ certification, this indicates that the product meets specific standard requirements in terms of safety, reliability, and other aspects, providing assurance for user use.

Packaging details: Using brand new original and factory sealed packaging, it can effectively prevent the product from being damaged or affected by moisture during transportation and storage, ensuring that the product received by the user is in the best condition.

Product size and weight:

Net height: 50mm

Net length: 230mm

Net width: 165mm

Net weight: 2kg, moderate size and weight, convenient for installation and integration in various devices, and easy to transport and carry.

Product Overview

ABB 3BHE004385R0001 UNS 0884a, V1 is a current sensor designed specifically for precise measurement of high currents, playing a key role in power monitoring in the industrial field. Its rated current measurement range is 2000A, which can adapt to various complex current monitoring scenarios and provide key data support for the stable operation of various systems. From the appearance, the compact design makes it easy to install inside various devices without taking up too much space.

Brand background

ABB Group is a multinational industrial energy production company established in 1988 through the merger of ASEA and BBC, headquartered in Zurich, Switzerland. In its development process, ABB has continuously innovated and broken through, launching many industry influential products, such as the Azipod electric propulsion system launched in 1990 and the digital solution product ABB Ability launched in 2017 ™ Wait. ABB’s business is extensive, covering multiple fields such as electrification, sports, and process automation. It has numerous customers in 165 countries worldwide and has established an excellent brand image with advanced technology and strict quality control. This current sensor is a reflection of ABB’s high-quality and high-performance brand.

Core functions

Accurate current measurement: It can accurately measure a current of 2000A with extremely high measurement accuracy, providing accurate current data for the system and helping engineers accurately judge the operating status of the system. For example, in large power equipment, real-time monitoring of current can ensure stable operation of the equipment within the rated current range.

Signal transmission and conversion: Convert the measured current signal into an electrical signal that is easy to process and transmit, facilitating connection and interaction with other devices such as control systems, monitoring instruments, etc., to achieve remote monitoring and analysis of data.

Working principle

This current sensor operates based on the principle of electromagnetic induction. When the measured current passes through the primary winding of the sensor, an alternating magnetic field is generated in the iron core. Under the action of this alternating magnetic field, the secondary winding will induce an induced electromotive force proportional to the primary current, thereby generating an induced current. By measuring and processing the secondary induced current, the high current value passing through the primary winding can be accurately calculated, achieving precise monitoring of the 2000A current.

Key advantages

High quality guarantee: Originating from Sweden and inheriting ABB’s strict production process and quality control system, the product has high reliability and can operate stably for a long time in harsh environments, reducing losses caused by equipment failures.

Authoritative certification endorsement: Possessing CO.CQ certification proves that it meets specific standards in terms of safety, reliability, and other aspects, allowing users to feel more at ease during use.

Flexible procurement plan: The minimum order quantity is only 1 piece, and there is a daily supply capacity of 10 pieces, which can meet both large-scale project procurement and small-scale testing needs, reducing the procurement threshold.

Convenient installation design: Moderate size (height 50mm, length 230mm, width 165mm) and lightweight (2kg) make it easy to install and integrate in various devices, and also convenient for transportation.

Precautions

Installation environment: It should be installed in a dry and well ventilated environment, avoiding places with high temperature, high humidity, and strong electromagnetic interference, to prevent affecting the measurement accuracy and service life of the sensor.

Wiring specifications: Strictly follow the product manual for wiring operations, ensure that the wiring is firm and correct, and avoid measurement errors or equipment damage caused by wiring errors.

Regular maintenance: Regularly inspect and calibrate sensors to ensure their measurement accuracy remains within the specified range. It is generally recommended to perform professional calibration every certain period of time (such as six months or one year).

Application scenarios

Power monitoring: used in power plants, substations and other power facilities to monitor the current of transmission lines, transformers and other equipment, ensure the safe and stable operation of the power system, timely detect abnormal fluctuations in current, and prevent faults from occurring.

Industrial automation: In automated production lines in the manufacturing industry, the current of equipment such as motors and frequency converters can be monitored. Through the analysis of current data, intelligent control and maintenance of equipment can be achieved, such as determining whether the motor is overloaded based on changes in current, and providing early warning and maintenance.

Municipal engineering: In facilities such as municipal pumping stations and air conditioning refrigeration systems, monitoring current is used to ensure the normal operation of equipment and optimize energy efficiency. For example, in the air conditioning system of large shopping malls, the operating parameters of refrigeration equipment are adjusted by monitoring current to achieve energy-saving operation.

Transportation: In the charging facilities of electric vehicle charging stations, electric buses, and trucks, the charging current is monitored to ensure the safety and stability of the charging process and prevent damage to the battery caused by overcurrent charging.

Product overview

ABB UAD206A101 is a programmable logic controller (PLC) specifically designed for industrial environments. In the industrial automation system, PLC plays a core control role, and UAD206A101, with its excellent performance, has become a key equipment for achieving efficient and precise control in many industrial scenarios. It is essentially an electronic system that performs numerical operations and can precisely control various complex industrial processes based on preset programs.

Core functional characteristics

Powerful logical operations and sequence control: Equipped with programmable memory internally, it can store instructions for executing logical operations and sequence control. On industrial production lines, it can accurately coordinate the start and stop sequence of various equipment. For example, on automotive parts assembly production lines, according to preset processes, it controls the robotic arm to grasp and assemble parts in sequence, ensuring orderly production and greatly improving production efficiency and product quality.

Flexible timing and counting functions: with precise timing and counting capabilities. In the process of chemical reactions, precise time can be set to control the reaction duration and ensure that the chemical reaction proceeds fully and stably; In the product packaging process, the counting function is used to count the number of packages, achieving automated packaging counting and quality control.

Integration of Analog and Digital Signal Processing: Supports digital or analog input/output, seamlessly connecting various sensors and actuators. In a smart factory, it can collect real-time analog sensor data such as temperature, pressure, flow rate, as well as digital signals such as equipment operation status and switch on/off. After internal processing, it outputs corresponding control signals to achieve comprehensive monitoring and precise control of the production process.

Highly reliable patented fault-tolerant mechanism: adopting patented fault-tolerant operation technology, by configuring two control modules to work together, the system reliability is greatly improved. When one control module fails, another can seamlessly take over the work immediately, ensuring uninterrupted industrial production processes. This is crucial for industries such as petrochemicals and power that require high continuity of production, effectively avoiding huge economic losses caused by equipment failures.

Accurate time synchronization function: supports external time synchronization using optional GPS satellite signals, ensuring time consistency between the system in different regions and devices. In large-scale industrial automation networks, various devices interact and collaborate based on precise and unified time, greatly improving the stability and coordination of system operation. For example, in distributed energy management systems, various power generation, transmission, and consumption equipment can efficiently cooperate based on precise synchronization time.

Convenient online image update: Provides fault-tolerant online image update function (for FCP270), allowing system program updates to be completed without shutting down the industrial production process. This means that without stopping production, system functions can be upgraded and vulnerabilities can be fixed in a timely manner, reducing production losses caused by downtime maintenance and meeting the modern industrial demand for efficient and sustainable production.

Technical specifications and parameters

Electrical parameters

Rated working voltage: Suitable for common industrial power supply standards, such as 24VDC, to ensure stable operation in complex industrial power grid environments.

Working current range: Depending on the actual load, it can stably carry the corresponding working current, ensuring the normal operation of the equipment under various working conditions.

Isolation voltage: With a high isolation voltage, such as 2500Vrms, it effectively isolates electrical interference between different circuits, prevents equipment from being affected by electrical fluctuations, and ensures system safety and reliability.

Application area 

Manufacturing industry: In the field of electronic manufacturing, equipment control is used for automated production lines, such as mobile phone assembly production lines, to accurately control the movements of equipment such as surface mount machines and welding robots, achieving efficient and high-quality production of electronic products; In the mechanical processing industry, the operation of machine tools can be controlled, and parameters such as tool motion trajectory and cutting speed can be accurately controlled according to processing technology requirements to ensure the machining accuracy of mechanical components.

Energy industry: In oil and gas extraction, monitoring and controlling various extraction equipment and transmission pipelines, real-time monitoring of pressure, flow rate and other parameters, to ensure the safety of oil and gas production and transportation; In the power system, it is used for substation automation control, grid scheduling, etc., to achieve remote monitoring and intelligent control of power equipment, and to improve the stability and reliability of power supply.

Chemical and pharmaceutical industries: In the chemical production process, controlling chemical reaction conditions such as temperature, pressure, acidity, etc. ensures stable quality of chemical products; In the pharmaceutical industry, strict control is exercised over drug production equipment and processes to meet drug production quality standards and ensure drug safety and effective production.

Municipal and Environmental Protection: In urban sewage treatment plants, control the operation of water pumps, aeration equipment, etc. to achieve automation of sewage treatment; In smart buildings, managing lighting, air conditioning, elevators and other systems to achieve optimized management and intelligent control of building energy, improve the efficiency of urban infrastructure operation and residents’ living comfort.