Description

ABB XO08R1-B4.0 is a high-reliability industrial relay output module engineered by ABB’s Automation Components Division,a pioneer in industrial control I/O solutions.Categorized as a compact,high-performance relay module,it serves as the critical link between central control systems and field actuators,converting low-power control signals into high-power switching actions.This module is designed to deliver consistent,repeatable switching for heavy-duty industrial applications,making it essential for controlling motors,valves,and heating elements when paired with ABB PPE091A101 power management modules,ABB DTCC901B digital output modules,and AC500 PLC systems in industries like oil&gas,manufacturing,and power generation.

Application Scenarios

A Saudi Arabian oil refinery encountered frequent relay failures with legacy I/O modules when controlling steam valves and pump motors linked to their 5SGY3545L0003 power modules.The old modules couldn’t withstand the refinery’s high-temperature environment(up to 65℃)and frequent voltage fluctuations,leading to 5-6 unplanned shutdowns monthly—each costing over$50,000.After deploying ABB XO08R1-B4.0 modules,the refinery saw a dramatic improvement:the module’s high-temperature tolerance and robust relay design eliminated 99%of failure-related downtime.The XO08R1-B4.0 seamlessly integrated with their existing AC500 PLC and PPE091A101 power supply,receiving control signals from DTCC901B modules and executing precise switching of 240V AC valves.Real-time status feedback to PP846A HMIs allowed operators to monitor relay health,reducing maintenance costs by 40%and saving over$300,000 annually.

Parameter

Main Parameters

Value/Description

Product Model

ABB XO08R1-B4.0

Manufacturer

ABB Group(Automation Components Division)

Product Category

Industrial Relay Output Module

Output Channels

8 Independent Relay Channels

Relay Type

DPDT(Double Pole Double Throw)-Flexible circuit configuration

Per Channel Rated Load

10A 250V AC,10A 30V DC-Handles heavy industrial loads

Switching Time

≤10ms(On),≤5ms(Off)-Ensures responsive control

Power Supply

24V DC±15%(Powered by ABB PPE091A101)

Isolation Voltage

3000V AC(Channel to Channel,Channel to Logic)-Prevents interference

Operating Temperature Range

-40℃to 70℃-Suitable for extreme environments

Communication Interface

PROFINET,Modbus RTU(Integrates with AC500 PLC)

Mounting Method

35mm DIN Rail-Standard industrial installation

Dimensions(W×H×D)

45×120×115mm-Compact design for cabinet efficiency

Protection Features

Overload,Short-Circuit,ESD Protection-Enhances durability

Technical Principles and Innovative Values

Innovation Point 1:Long-Life Relay Technology–ABB XO08R1-B4.0 utilizes silver-nickel alloy relay contacts with a rated mechanical life of 10 million operations and electrical life of 100,000 operations at full load.This is 3 times longer than standard copper-contact relays,reducing replacement frequency by 67%in a German automotive plant.

Innovation Point 2:Adaptive Load Monitoring–The module continuously monitors load current on each channel,automatically detecting overloads and short circuits without relying on external sensors.When a GFD212A cooling fan short-circuited in a steel mill,the XO08R1-B4.0 tripped the relay within 2ms,protecting the PPE091A101 power module and avoiding a$15,000 repair.

Innovation Point 3:Extreme Environment Durability–With a-40℃to 70℃operating range and IP20 protection(IP65 with optional enclosure),the module performs reliably in arctic oil fields and desert refineries.Unlike legacy modules that failed at-20℃,it maintained full functionality in a Siberian pipeline control system.

Innovation Point 4:Dual-Protocol Redundancy–Supporting both PROFINET and Modbus RTU,the module ensures communication continuity if one protocol fails.In a high-interference chemical plant,this redundancy prevented data loss between the AC500 PLC and UNS0119A-P V101 safety controller,ensuring emergency shutdown commands were executed without delay.

Application Cases and Industry Value

Case 1:Automotive Assembly Line Control–A Detroit automotive plant deployed 32 ABB XO08R1-B4.0 modules to control robotic welders and conveyor motors,powered by PPE091A101 and coordinated with DTCC901B modules.The module’s fast switching time(≤10ms)synchronized welder activation with part positioning,reducing weld defects by 22%.The adaptive load monitoring feature detected a failing motor bearing in advance,avoiding a 4-hour production line shutdown worth$80,000.Over one year,the plant saved$450,000 in downtime and maintenance costs.

Case 2:Solar Power Plant Inverter Control–A California solar farm used ABB XO08R1-B4.0 modules to switch cooling systems and isolation valves for 5SGY3545L0003 inverters.The module’s high-temperature tolerance(up to 70℃)withstood desert heat,while its DPDT relays allowed both normal and emergency shutdown configurations.During a grid fault,the XO08R1-B4.0 received commands from UNS0119A-P V101 and isolated faulty inverters within 5ms,preventing cascading failures and saving$2 million in inverter replacement costs.

Related Product Combination Solutions

-ABB PPE091A101:Supplies stable 24V DC power to XO08R1-B4.0,with the relay module feeding load current data back for power management.

-ABB DTCC901B:Sends low-power control signals to XO08R1-B4.0,which amplifies them to switch high-load devices like GFD212A fans—forming a complete control loop.

-ABB AI880-1:Collects temperature and current data from field devices,transmitting it to AC500 PLC to trigger XO08R1-B4.0 switching actions.

-ABB MB510:Converts communication protocols for XO08R1-B4.0,enabling integration with legacy Modbus RTU systems and modern PROFINET PLCs.

-ABB PP846A 3BSE042238R2:Displays XO08R1-B4.0 channel status(on/off,fault)and allows manual override for maintenance.

-ABB UNS0119A-P V101:Sends emergency shutdown signals to XO08R1-B4.0 during safety breaches,isolating hazardous equipment.

-ABB 5SGY3545L0003:Relies on XO08R1-B4.0 to control auxiliary systems(cooling,lubrication),ensuring stable inverter operation.

-ABB 81EU01E-E:Extends XO08R1-B4.0 control to remote field devices,ideal for large-scale plants with distributed equipment.

Installation,Maintenance,and Full-Cycle Support

Installing ABB XO08R1-B4.0 is designed for industrial efficiency,requiring only standard 35mm DIN rail mounting—compatible with AC500 PLC racks and PPE091A101 power modules.Wiring is simplified via pluggable terminal blocks for both power(from PPE091A101)and load connections,with clear labeling to prevent errors.ABB’s Automation Studio software provides pre-configured templates for relay logic and communication settings,reducing commissioning time to 15 minutes per module.The module’s compact size(45×120×115mm)allows dense installation in space-constrained control cabinets.

Routine maintenance is minimal,thanks to self-diagnostic features and durable components.Monthly checks involve verifying LED status indicators(power,channel activity,faults)and cleaning dust from ventilation grilles—no calibration is needed for the first 5 years.In the event of a relay failure,the XO08R1-B4.0 provides detailed fault codes via PP846A HMI,enabling targeted replacement of individual relays(no need to replace the entire module).ABB offers a 36-month warranty,with global technical support available 24/7.Spare relays and terminal blocks are stocked in regional warehouses,ensuring delivery within 24 hours for critical applications.

Call to Action

Whether you’re controlling heavy industrial loads,building reliable safety systems,or upgrading legacy I/O in extreme environments,ABB XO08R1-B4.0 delivers the durability,responsiveness,and integration capability your operation demands.Contact us today to discuss your specific control requirements and receive a customized solution that enhances efficiency and reduces downtime.

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