Product Overview: The ABB 216AB61 Overcurrent Protection Relay

The ABB 216AB61, with the manufacturer part number HESG324013R101, is a versatile and highly reliable single-phase overcurrent protection relay from the renowned ABB SPAC product family. Designed for the demanding environments of industrial and utility electrical systems, this relay provides essential protection for motors, transformers, capacitors, and feeders against damage caused by overcurrent conditions.

As a cornerstone of electrical protection schemes, the SPAC 102 relay combines robust construction with precise electromechanical operation. Its timeless design ensures longevity and stability, making it a trusted component in switchgear, control panels, and power distribution systems worldwide. This product page provides an in-depth look at its features, technical specifications, and application guidance to help you make an informed decision.

Why Choose the ABB 216AB61 Relay?

• Proven Reliability: Electromechanical design ensures stable operation without software glitches or firmware updates.

• High Accuracy: Precise time-current characteristics for selective coordination, preventing unnecessary tripping.

• Rugged Construction: Built to withstand electromagnetic interference, vibration, and harsh industrial conditions.

• Easy Installation & Setting: Simple-to-use dials for current and time multiplier settings, reducing commissioning time.

• Global ABB Support: Backed by ABB's global network for technical support and service.

Detailed Technical Specifications

The following table outlines the comprehensive technical specifications for the ABB 216AB61 / HESG324013R101 relay.

In-Depth Functional Description

Core Operating Principle

The 216AB61 is an induction disc relay. The operating current from the Current Transformer (CT) secondary flows through a coil, creating a magnetic field that induces eddy currents in an aluminum disc. The interaction of these magnetic fields produces a torque that rotates the disc. The disc's rotation is opposed by a control spring.

Under normal load conditions, the torque is insufficient to overcome the spring tension. When an overcurrent occurs, the increased torque causes the disc to rotate. The speed of rotation is proportional to the square of the current. After a pre-set angle of rotation, the disc closes the main trip contact, sending a signal to the circuit breaker's trip coil to isolate the fault.

The Time Multiplier Setting (TMS) adjusts the initial angular position of the moving contact, thereby setting the total time taken for the disc to travel and close the contact. The Plug Setting (PS) adjusts the number of turns on the relay's operating coil, effectively changing the current level at which the relay begins to operate.

Time-Current Characteristic Curves

A key feature of the 216AB61 is its selectable operating characteristics. This allows engineers to coordinate the relay with other protective devices upstream and downstream, ensuring that only the breaker closest to a fault trips, minimizing outage impact.

• Standard Inverse (SI): Used for general overcurrent protection of feeders and lines.

• Very Inverse (VI): Ideal for protecting cables and transformers where higher fault currents demand faster operation.

• Extremely Inverse (EI): Best suited for the protection of fuses and motor circuits, providing excellent coordination with melting fuses.

Typical Applications

The ABB 216AB61 relay is a versatile component used across various sectors:

• Industrial Motor Protection: Protecting high-value AC motors from locked-rotor conditions and prolonged overloads.

• Transformer Protection: Serving as a backup overcurrent protection for power and distribution transformers.

• Feeder & Cable Protection: Protecting distribution feeders in industrial plants, commercial buildings, and utility substations.

• Capacitor Bank Protection: Guarding against overcurrents in power factor correction capacitor banks.

• Integration in Switchgear: A core component in LV and MV switchgear assemblies from ABB and other manufacturers.
  
  

Installation, Wiring, and Commissioning Guide

Mounting Instructions

1. Panel Preparation: Cut a standard-sized rectangular hole in the panel as per the relay's dimensional drawing.

2. Insertion: Insert the relay from the front of the panel.

3. Securing: Use the provided mounting clamps or screws to secure the relay firmly to the panel. Ensure there is no undue stress on the relay case.

Wiring Guidelines

• CT Circuit: Connect the secondary of the Current Transformer (CT) to the relay's current input terminals. It is critical to never open-circuit a CT secondary while the primary is energized. Always ensure the CT circuit is shorted when the relay is removed.

• Trip Circuit: Connect the relay's NO (Normally Open) main contact in series with the trip coil of the circuit breaker and the DC control supply. A protective varistor may be recommended across the trip coil to suppress voltage surges.

• Auxiliary Indicator: The flag indicator contact can be wired to a remote alarm panel to signal that the relay has operated.

Commissioning and Testing

1. Visual Inspection: Check for any physical damage during transit.

2. Insulation Resistance Test: Perform a Megger test between all interconnected terminals and earth.

3. Setting Verification: Manually set the Plug Setting (PS) and Time Multiplier Setting (TMS) to the values calculated in the protection coordination study.

4. Primary Injection Test: The most accurate test method. Inject a high current (representing a fault) directly into the CT primary and measure the relay's operating time. Compare it with the theoretical value from the time-current curve.

5. Secondary Injection Test: A more common method. Use a relay test set to inject current directly into the relay's terminals and verify its pick-up current and timing accuracy.

Comparison with Modern Digital Relays

While digital/numerical relays offer advanced features like communication (IEC 61850), event logging, and multiple protection functions, the ABB SPAC 102 electromechanical relay holds its ground due to:

• Simplicity: No complex programming required.

• Cost-Effectiveness: Significantly lower cost for basic overcurrent protection needs.

• Robustness: Immune to cyber threats and less susceptible to damage from voltage transients.

• Predictability: Its operation is purely physical and easily understood.

For applications where basic, reliable, and cost-effective overcurrent protection is paramount, the SPAC 102 remains an excellent choice.

Frequently Asked Questions (FAQ)

Q1: What is the difference between HESG324013R101 and 216AB61?
A: They refer to the same physical device. HESG324013R101 is the manufacturer's internal part number, while 216AB61 is the ordering code used by distributors and customers for procurement.

Q2: Where can I find the manual or datasheet for the ABB 216AB61?
A: You can download the official ABB manual for the  216AB61 from the ABB website or reputable technical portals. Search for "   HESG324013R101 (216AB61) Product Manual (PDF) ". We also offer it for download on this page (link to be provided by the website administrator).

Q3: Can this relay be used for both 50Hz and 60Hz systems?
A: The relay is typically calibrated for a specific frequency (50Hz or 60Hz). Please check the nameplate on the device or the specific ordering code to confirm its frequency rating. Using it on the wrong frequency system can affect its timing accuracy.

Q4: How do I calculate the correct settings for my application?
A: Settings are determined by a protection coordination study. This involves analyzing the fault currents at different points in your network and setting the PS and TMS so that the relay operates only for faults in its designated zone and with the correct time delay relative to other protective devices. Consult with a qualified protection engineer.

Q5: Is this product still manufactured by ABB?
A: The SPAC series is a classic product line. While it may be in a mature phase of its lifecycle, it is often still supported by ABB and its distributors. New old stock (NOS) and reliable refurbished units are commonly available on the market.

Conclusion & Call to Action

The ABB HESG324013R101 (216AB61)  overcurrent protection relay represents the gold standard in electromechanical protection. Its simplicity, durability, and precise operation have made it a staple in electrical infrastructure for decades. Whether you are maintaining existing equipment or designing a new system that values fundamental reliability, this relay is a proven solution.

Ready to Secure Your Power System?

Contact us today for a competitive price, availability, and technical support for the ABB 216AB61 relay. Our experts are ready to assist you with your procurement and application needs.