ABB 500PB101 1MRB200064/C Binary Output Module

I. Overview

• In motor control circuits in the chemical industry, the device can real-time monitor the operating current and voltage of motors. When a motor experiences overload (current exceeding 120% of the rated value) or locked rotor (current exceeding 600% of the rated value), it triggers trip protection within 0.1 seconds to prevent motor winding burnout.

• In transformer power distribution systems in the metallurgical industry, it can monitor the current and temperature of the high and low-voltage sides of transformers. When the transformer oil temperature exceeds 85°C or an inter-turn short circuit occurs, it quickly cuts off the power supply to prevent transformer fire or explosion.

• In UPS power distribution circuits in data centers, it can monitor input/output voltage and frequency. When voltage fluctuation exceeds ±10% or frequency deviates from 50Hz ±0.5Hz, it issues an alarm and switches to the backup power supply to ensure continuous power supply for servers.

• The 500PB101 1MRB200064/C adopts a compact industrial-grade housing with dimensions of 180mm×120mm×80mm. It is compatible with 19-inch standard racks or embedded installation in distribution boxes, saving installation space.

• The housing is made of UL94 V-0 grade flame-retardant ABS material, with an IP40 protection rating, which can resist dust and water splashes in industrial sites.

• It operates within a temperature range of -25°C to 70°C and a relative humidity of 5% to 95% (non-condensing), making it suitable for both low-temperature outdoor distribution rooms and high-temperature workshop distribution boxes.

• Internally, it adopts an independent three-module design of "sampling-calculation-execution", combined with an electromagnetic shield, which effectively reduces the impact of power grid harmonics and external electromagnetic interference on protection accuracy.

• The Mean Time Between Failures (MTBF) is ≥200,000 hours (per Telcordia standard, at 25°C), meeting the "long-cycle, high-reliability" operation requirements of industrial power systems.

• Additionally, it is compatible with the ABB Ability™ Power Monitoring Cloud Platform, supporting remote configuration of protection parameters and fault diagnosis to reduce operation and maintenance costs.

II. Technical Parameters

1. Electrical Parameters

2. Protection Function Parameters

3. Monitoring and Communication Parameters

4. Environmental and Reliability Parameters

III. Functional Characteristics

1. Accurate Protection for All Scenarios

• Dual Protection Against Overload and Short Circuit: Aiming at the overload and short-circuit risks of motors, transformers, and other equipment, it adopts a protection logic combining inverse time-lag and instantaneous trip. In the control of pump loads in the chemical industry:

• When a pump experiences slight overload (current at 110% of the rated value), the device trips with a 5-second delay based on the inverse time-lag characteristic to avoid false operation caused by transient overload.

• When a severe short circuit occurs (current at 600% of the rated value), it triggers an instantaneous trip within 0.05 seconds to cut off the fault circuit and prevent equipment burnout.
  Example: In a chemical plant, a centrifugal water pump (rated current 50A) had its current rise to 300A due to impeller jamming. The device tripped within 0.08 seconds, preventing pump winding burnout and reducing maintenance costs by 50,000 yuan.

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• Ground and Leakage Protection: It supports zero-sequence current transformer (ZCT) or residual current detection, enabling accurate identification of equipment ground faults (e.g., motor winding grounding, cable insulation damage). In underground power distribution systems in the mining industry:
  When cable insulation damage causes a ground current of 10A (set threshold 8A), the device trips within 0.1 seconds and issues an audible and visual alarm to prevent electric shock accidents or gas explosions caused by ground faults.
• Protection Against Voltage and Frequency Abnormalities: It real-time monitors power grid voltage and frequency, and quickly triggers protection when there is overvoltage (e.g., voltage rising to 120% of the rated value due to lightning strikes), undervoltage (e.g., voltage dropping to 80% of the rated value due to sudden load increase), or frequency deviation. In data center scenarios:
  When the power grid voltage drops sharply to 180V (rated 220V), the device issues an alarm within 0.2 seconds and triggers UPS switching, ensuring uninterrupted power supply for servers and avoiding data loss.

2. Real-Time Monitoring of All Parameters

• High-Precision Electrical Parameter Measurement: Equipped with a 24-bit AD sampling chip, it achieves a measurement accuracy of ±0.2% for current and voltage, and can real-time monitor over 15 parameters including three-phase current, voltage, power factor, and active/reactive power. In transformer power distribution systems in the metallurgical industry:
  The device can real-time monitor the current (accuracy ±0.1%) and power factor (accuracy ±0.5%) of the high and low-voltage sides of the transformer, calculate the transformer load rate, and issue an early warning when the load rate exceeds 80% to remind operation and maintenance personnel to adjust load distribution and prevent transformer overload.

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• Accurate Fault Data Recording: It automatically stores key information (current, voltage, time) at the time of a fault with a recording accuracy of 1ms, providing a basis for fault analysis. In motor fault troubleshooting in intelligent manufacturing factories:
  Operation and maintenance personnel checked the fault records through the device and found that the current reached 300A (rated 50A) when the motor tripped. This indicated a locked rotor fault, leading to the identification of motor reducer jamming. Maintenance time was reduced from the traditional 4 hours to 1 hour.
• Electric Energy Metering and Statistics: It supports cumulative metering of active and reactive electric energy (accuracy ±0.5%) and can generate daily/monthly/annual electric energy reports. In power distribution systems of commercial buildings:
  Property management uses the device to count electricity consumption of each floor, realizing electricity cost allocation and energy-saving optimization, and reducing electricity waste by 10% annually.

3. High Flexibility for System Adaptation

• Customizable Protection Parameter Setting: It supports setting of protection parameters (e.g., overload current threshold, trip time) via buttons or software (Modbus protocol), adapting to the protection needs of different types of equipment (motors, transformers, cables). In power distribution for welding robots in automobile factories:

• For the robot motor (rated current 20A), the overload threshold is set to 24A (120% of the rated value) and the trip time to 0.5 seconds.

• For the power distribution cable (rated current 100A), the short-circuit threshold is set to 500A (5 times the rated value) and the trip time to 0.05 seconds.
  This achieves "one device for multiple equipments" protection.

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• Compatibility with Multiple Communication Protocols: It supports RS485 (Modbus RTU) and Ethernet (Modbus TCP) communication, and can be connected to the ABB Ability™ cloud platform or third-party SCADA systems (e.g., Siemens WinCC, Schneider Citect). In power distribution monitoring of large chemical parks:
  Over 100 devices are connected to the central SCADA system via Modbus TCP. Operation and maintenance personnel can real-time check the status of all power distribution circuits in the central control room and remotely modify protection parameters without on-site operations, improving operation and maintenance efficiency by 80%.
• Expansion Interface Adaptation: The 4-channel digital input can be connected to external signals such as cabinet door interlocks and manual trip buttons; the 2-channel analog input can be connected to temperature sensors (e.g., transformer oil temperature sensors) to realize "electrical parameter + physical parameter" joint protection. In power distribution systems of photovoltaic inverters:
  The device collects inverter temperature via analog input, and triggers trip protection when the temperature exceeds 60°C and the current exceeds the rated value, preventing inverter damage due to overheating.

4. High Reliability for Operation Guarantee

• Wide Environmental Adaptability: The wide temperature design (-25°C~70°C) allows stable operation without protection accuracy drift in both low-temperature outdoor distribution rooms (-20°C in northern winters) and high-temperature workshops (65°C in southern summers). The IP40 protection rating resists dust and water splashes, enabling 1-year fault-free operation in power distribution environments of textile factories (high dust) or food processing plants (cleaning water splashes).

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• Electromagnetic Interference Resistance: Complying with the EN 55024 immunity standard (ESD protection ±8kV, EFT protection ±2kV), it has a protection operation error of ≤5% in environments with strong electromagnetic interference (e.g., frequency converters, welding machines). In the power distribution system of rolling mills in steel plants:
  Despite the presence of a large number of frequency converters (generating high-frequency harmonics) on-site, the device can still accurately monitor current and trigger protection operations without errors.
• Redundancy and Fault Self-Recovery: It supports dual auxiliary power input (AC/DC 85-265V). When one power supply fails, the other switches seamlessly (switching time ≤10ms) to ensure uninterrupted operation of the device. It has a built-in hardware fault self-diagnosis function: when a sampling module fault is detected, it issues an alarm without triggering false trips, and uploads fault information to prevent "fault expansion" in the system.