ABB REX010 HESG324426R0001: Electronic Control Unit

Application Scenarios:

In a large water treatment plant, the reliable operation of high-voltage pump motors is essential for maintaining continuous water supply. A voltage sag or phase imbalance could cause motor overheating and catastrophic failure, leading to extended downtime and significant repair costs. The ABB REX010 HESG324426R0001​ module is integrated into the motor control center (MCC) as a dedicated protection relay. It continuously monitors the motor’s current, voltage, and thermal capacity. When it detects an abnormal condition, such as a sustained overload or a phase loss, the module’s logic circuitry activates within milliseconds, sending a trip signal to the circuit breaker to safely disconnect the motor. This precise, automated protection prevents damage to the expensive pump motor, directly addressing the key pain points of equipment safety, unplanned downtime, and maintenance cost overruns.

Technical Principles and Innovative Values:

Innovation Point 1: Advanced Microprocessor-Based Protection Logic. The ABB REX010 HESG324426R0001​ moves beyond simple electromechanical protection by utilizing a dedicated microprocessor. This allows it to implement complex, time-dependent protection characteristics (like inverse-time overload curves) that closely match the thermal profile of the equipment it protects. It can differentiate between harmless transient surges and genuine fault conditions, preventing nuisance trips while ensuring fast response to real faults, thereby enhancing both protection and operational continuity.

Innovation Point 2: Integrated Diagnostics and Condition Monitoring. Beyond basic trip functionality, the module incorporates self-diagnostics and detailed condition monitoring. It can track thermal memory (simulating motor heating and cooling), log the number of operations, and time-stamp the last fault event. This data provides maintenance teams with predictive insights, moving from reactive “fix-it-when-it-breaks” to proactive “maintain-it-before-it-fails” strategies, significantly reducing unplanned outages.

Innovation Point 3: Modular and Configurable Design for Flexible Integration. The REX010 HESG324426R0001​ is designed for flexibility. Its parameters, such as current setpoints, trip delays, and function enables, are often configurable via DIP switches or a simple interface. This allows a single module type to be applied to motors or circuits of different sizes and criticalities across a plant, simplifying spare parts inventory and technician training. Its DIN-rail form factor ensures easy integration into new or existing control panels.

Application Cases and Industry Value:

A mining operation experienced frequent, unexplained shutdowns of its critical conveyor belt drives, each hour of downtime costing tens of thousands in lost production. The problem was traced to outdated, non-adjustable thermal overload relays that couldn’t handle the legitimate, short-duration current spikes during start-up under full load. They replaced these relays with configurable ABB REX010 HESG324426R0001​ protection modules. Engineers precisely tuned the trip curves to allow for high-inertia start-ups while providing stringent protection against genuine overloads. The result was the complete elimination of nuisance trips related to starting. Furthermore, by analyzing the modules’ logged data, the team identified a motor with gradually rising operating temperatures, scheduling a bearing replacement during a planned maintenance window and avoiding a potential catastrophic failure. The maintenance superintendent confirmed, “Installing the REX010 HESG324426R0001​ modules turned a major operational headache into a non-issue. We gained reliable protection and valuable diagnostic data, boosting both uptime and our maintenance planning capability.” This demonstrates the module’s value in maximizing production availability, enabling predictive maintenance, and protecting capital-intensive equipment.

Related Product Combination Solutions:

ABB CM-PFE​ Power Factor Correction Controller: Often used in the same switchgear to optimize plant power quality, while the REX010 HESG324426R0001​ protects individual feeders.

ABB UPS Series​ Uninterruptible Power Supplies: Provides clean, backup power to control circuits containing critical protection modules like the REX010 HESG324426R0001. ensuring they remain operational during main power disturbances.

ABB AF/AT Circuit Breakers: The REX010 HESG324426R0001​ module typically sends its trip command to a circuit breaker like an ABB SACE model, forming a complete coordinated protection scheme.

ABB CMA Communication Module: An optional add-on that can be paired with protection relays to enable communication of the REX010 HESG324426R0001’s status and data to a SCADA or DCS system over protocols like Modbus.

ABB DCS / PLC Systems (e.g., AC 800M, Symphony Plus): The high-level control system that may receive alarms and status from the REX010 HESG324426R0001​ modules for plant-wide monitoring and control.

ABB Current Transformers (CTs): These sensors provide the scaled current measurement signals to the REX010 HESG324426R0001​ module, forming the essential sensing link in the protection chain.

ABB Relion Protection Relay Series (e.g., 615. 620 series): Represents ABB’s newer generation of advanced, fully-featured protection relays, showing the technological lineage and potential upgrade path from dedicated modules.

Installation, Maintenance, and Full-Cycle Support:

Installation of the ABB REX010 HESG324426R0001​ is designed for efficiency. The module is mounted on a standard DIN rail within a protected enclosure. Wiring involves connecting the control power supply, the input signals from current or voltage transformers, and the output contacts to the trip coil of a circuit breaker or to alarm indicators. Critical steps include verifying the CT circuit is never open-circuited, setting the configuration DIP switches or parameters according to the protected load’s specifications, and performing functional tests to validate the trip and alarm operations before placing the system into service.

Maintenance is primarily preventative and diagnostic. The module’s solid-state design requires no periodic calibration. Routine checks should include visual inspection for any signs of overheating on terminals, verification that status LEDs are functioning correctly, and ensuring the ventilation is not obstructed. The most valuable maintenance activity is periodically downloading and reviewing any event logs or thermal memory data stored in the module to assess equipment health. If a module fault is indicated, it is generally replaced as a unit. We supply fully tested and certified ABB REX010 HESG324426R0001​ modules. Our technical support can assist with configuration guidance, wiring verification, and integration advice to ensure this critical protection component functions flawlessly within your electrical infrastructure.

Contact us for your ABB REX010 HESG324426R0001 requirements and for expert support in protecting your critical electrical assets.