Application Scenarios
At a copper mine in Chile, repeated failures of 415 V slurry pump motors caused costly production halts due to undetected phase imbalances and bearing overheating. Legacy thermal overload relays offered no data or early warnings. After installing the ABB REM615E_1G HBMBCAAJABC1BNN11G, engineers leveraged its negative-sequence current monitoring and adaptive thermal model to detect developing stator faults weeks in advance. During one incident, the relay’s integrated arc flash detection—triggered by an internal short during startup—tripped the feeder breaker in under 5 ms, preventing catastrophic motor explosion and saving an estimated $ 350.000 in equipment and downtime. In this harsh environment, the REM615E_1G HBMBCAAJABC1BNN11G transformed motor protection from reactive tripping into proactive asset intelligence.
Technical Principles and Innovative Values
Innovation Point 1: Real-Time Thermal Modeling with Ambient Compensation – The REM615E_1G HBMBCAAJABC1BNN11G uses a dual thermal model (winding and rotor) that dynamically adjusts cooling constants based on real-time load and ambient temperature input, preventing nuisance trips during frequent starts while accurately predicting insulation degradation.
Innovation Point 2: Integrated Arc Flash Mitigation Without External Logic – Direct connection to fiber-optic arc sensors enables sub-5 ms trip commands via dedicated high-speed outputs—bypassing communication delays and meeting NFPA 70E requirements for personnel safety.
Innovation Point 3: IEC 61850 Process Bus Ready for Digital Substations – Native support for Sampled Values (SV) allows direct connection to merging units, enabling synchronized phasor measurements across multiple motors for system-wide diagnostics.
Innovation Point 4: Cyber-Hardened Architecture – Features secure boot, encrypted firmware updates, role-based access, and audit trails compliant with NERC CIP and IEC 62443—critical for industrial facilities facing rising OT security threats.
Application Cases and Industry Value
A North American pulp & paper mill retrofitted 45 critical motors—including refiners, blowers, and chip conveyors—with ABB REM615E_1G HBMBCAAJABC1BNN11G relays. The built-in starts-per-hour (66) and locked-rotor (50LR) protection prevented mechanical damage during frequent process upsets, reducing motor rewind costs by 60%. Simultaneously, energy data streamed via IEC 61850 to their PI System enabled identification of three oversized motors, leading to right-sizing and annual savings of $ 84.000 in electricity. In a Middle Eastern desalination plant, the relay’s sensitive earth-fault detection (51N down to 0.02x In) located intermittent ground faults in submersible pumps before saltwater ingress caused total failure—avoiding unscheduled shutdowns in a water-critical region.
Related Product Combination Solutions
Maximize motor protection and automation synergy by integrating the REM615E_1G HBMBCAAJABC1BNN11G with these ABB Relion® and auxiliary products:
REF615A_E: Feeder protection relay for upstream coordination and backup.
OPT11: Dedicated optical arc flash sensor module with 10-meter fiber cable.
PCM600: Engineering tool for configuration, testing, and disturbance recording analysis.
TTX01: Precision time synchronization unit (IRIG-B, PTP) for event correlation.
LTX01: Local operator interface for on-device control and status viewing.
RED615: Transformer protection relay for motor-driven transformer-fed systems.
615 BIO Module (e.g., BIO615): Expandable binary I/O for complex interlocking with MCCs.
Relion Manager: Centralized relay management and firmware update platform.
Installation, Maintenance, and Full-Cycle Support
Installing the ABB REM615E_1G HBMBCAAJABC1BNN11G requires correct CT polarity, shielded cabling grounded at one end, and proper arc sensor fiber routing (avoid sharp bends). Commissioning is streamlined using PCM600’s motor-specific templates, which auto-populate thermal curves and protection thresholds based on nameplate data. The front-panel LCD provides real-time motor status, fault flags, and metering—even during network outages.
For maintenance, the relay performs continuous self-diagnostics and logs all events with 1 ms resolution, including waveform captures (COMTRADE) for post-fault analysis. Firmware updates are performed securely over Ethernet without physical access. Our engineering team offers motor coordination studies, arc flash risk assessments, and cybersecurity hardening services. Every REM615E_1G HBMBCAAJABC1BNN11G we supply undergoes full functional validation—including thermal simulation, arc detection timing, and IEC 61850 interoperability testing—and includes a calibration certificate and 5-year warranty. With global ABB-certified support and remote diagnostics capabilities, you ensure decades of reliable, intelligent motor protection.
Contact us for a customized solution—engineered for motor longevity, certified for personnel safety, and built to drive the future of industrial electrification.
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