Product Core Brief
- Model: RXTUG 22H, full OEM part number: 1MRK000592-A
- Brand: ABB Hitachi Energy
- Series: ABB COMBIFLEX modular secondary relay system dedicated auxiliary power converter
- Core Function: Isolated wide-input DC-DC power supply module designed exclusively to power all COMBIFLEX plug-in measuring and protection relays (RXIDK, RXEDK, RXPPK, RXIIK, RXDS4, RXHL series). It converts unstable wide-range station DC auxiliary power (24–250 VDC) into stable isolated 24 VDC low-noise logic power for microprocessor-based COMBIFLEX relays, eliminating DC bus voltage fluctuation interference and providing galvanic isolation between station control power and sensitive relay measuring circuits. Built-in multi-stage hardware protection prevents relay damage from input overvoltage, reverse polarity and overload short circuits.
- Product Type: COMBIFLEX / DIN rail mounted isolated DC-DC auxiliary power converter
- Key Specs: Wide input DC range 24 VDC ~ 250 VDC; fixed isolated 24 VDC output; rated output power 22 W; full galvanic isolation between input and output; integrated reverse polarity, overvoltage, overload, short-circuit auto-locking protection; standard COMBIFLEX 35 mm DIN rail mounting; compatible with all COMBIFLEX plug-in relay bases
- Note: Mature legacy platform component, still active production for conventional power plant and distribution substation COMBIFLEX relay panel renovation; factory-sealed new modules and fully bench-load-tested surplus units are widely supplied for thermal power, hydropower, wind farm and industrial MV switchgear maintenance retrofits. It is a mandatory matching accessory for all COMBIFLEX microprocessor relays that require stabilized 24V internal logic power.
Key Technical Specifications
| Parameter | Value |
|---|---|
| Full OEM Article Code | RXTUG 22H 1MRK000592-A |
| DC Input Operating Range | 24 VDC ~ 250 VDC (covers standard substation 48V, 110V, 220V station DC control power) |
| Nominal DC Output | Stabilized 24 VDC isolated low-noise logic power |
| Maximum Continuous Output Power | 22 W |
| Output Rated Current | 0.92 A at 24 VDC full load |
| Galvanic Isolation Rating | 2 kV AC functional isolation between input high-voltage DC and output low-voltage relay logic circuits |
| Built-in Hardware Protection Suite | Input reverse polarity blocking, input overvoltage lockout, output overload current limiting, output short-circuit auto shutdown with automatic recovery |
| Front Panel Status Indicator | Green RUN LED (steady on = normal power output; flashing = fault lockout) |
| Mechanical Mounting | Standard 35 mm DIN rail mounting, compatible with COMBIFLEX modular cabinet layout |
| Ambient Operating Temperature | -20 °C ~ +55 °C continuous cabinet operation; storage temperature -40 °C ~ +70 °C |
| Humidity Tolerance | Max 75% RH non-condensing, indoor substation control room rated |
| Overall Dimensions | 165 mm H × 56 mm W × 70 mm D |
| Net Weight | Approx. 500 g |
| Compliance Standards | IEC 60255 secondary protection equipment standard, IEC 61010 power supply safety standard, CE certified, RoHS compliant |
Product Introduction
The RXTUG 22H 1MRK000592-A is a purpose-built isolated DC-DC converter serving as the standard auxiliary power source for the entire ABB COMBIFLEX modular relay system, solving two critical pain points of traditional relay power supply schemes:
- Wide-Range DC Input CompatibilitySubstation station DC control power varies widely across different power plant designs (48 V, 110 V, 220 V DC). This single RXTUG 22H model accepts all these voltage ranges without hardware modification, unifying spare part inventory and eliminating the need to stock multiple power supply variants for different cabinet DC bus ratings.
- Galvanic Isolation & Stable Low-Noise Logic PowerAll COMBIFLEX microprocessor relays rely on precise low-noise 24 VDC to ensure accurate CT/VT signal measurement and stable protection algorithm operation. The isolation barrier completely blocks DC bus surge interference, voltage ripple and ground loop noise generated by switchgear breakers and large motor starters, avoiding false relay trips and measuring signal drift.
Built-in comprehensive self-protection logic safeguards both the converter and downstream COMBIFLEX relays:
- Reverse input polarity protection prevents instant circuit burnout if station DC wiring is misconnected;
- Overvoltage lockout cuts output when input DC voltage exceeds 270 VDC;
- Constant current limiting and auto-recovery short-circuit protection stop power output instantly if any relay internal circuit is shorted.
It is installed on the same DIN rail as COMBIFLEX plug-in relays (RXIDK, RXEDK, RXPPK, RXIIK, RXDS4 test switches) inside substation relay cabinets, supplying shared stabilized 24V logic power for up to 3–4 standard COMBIFLEX relays simultaneously. Without a functional RXTUG 22H, all connected measuring and protection relays will lose power and stop executing fault supervision functions.
QA & Testing SOP (Transparency Building)
- Incoming Visual Inspection: Cross-check full part number RXTUG 22H 1MRK000592-A and serial number against ABB power system spare parts database to reject counterfeit mismatched converters; inspect front RUN LED indicator, input/output terminal screw blocks, internal isolation transformer and conformal PCB coating for burn marks, salt corrosion or discoloration; record serial numbers and production batches for full traceability.
- Full Load Bench Test: Mount RXTUG 22H on standard DIN rail test bench, apply variable 24–250 VDC input power; connect simulated COMBIFLEX relay load banks to the 24 VDC output, run 24-hour cyclic full-load testing, simulate reverse polarity, overvoltage and output short-circuit faults to verify protection lockout and automatic recovery performance, confirm stable 24 VDC output voltage with minimal ripple under all input voltage conditions.
- Electrical Insulation Test: Use insulation resistance tester to confirm isolation resistance ≥ 10 MΩ between input DC high-voltage circuits and output 24 V logic circuits; test chassis ground continuity resistance below 0.5 Ω.
- Hardware Record Backup: Photograph input/output terminal pin definitions and DIN rail mounting dimensions for field wiring reference.
- Final QC Packaging: Wipe converter housing with anti-static microfiber cloth, cover all terminal screw blocks with insulating dust caps, place the unit into independent ESD shielding bag, attach unified printed QC test tag with technician ID and full 24-hour full-load test runtime timestamp, then pack into foam shockproof carton for long-distance power plant transportation.
Installation Pitfalls & 4-Step Replacement Guide
Common Installation Hazards
❗ Wide DC Input Voltage Misjudgment: The module supports 24–250 VDC input, but wiring must strictly match station DC polarity; reversed positive/negative terminals will trigger permanent input protection lockout and require power cycle reset.❗ Overload Output Risk: Do not connect more than 4 standard COMBIFLEX relays to one RXTUG 22H output; excessive load current will activate overload protection and cut off relay power supply.❗ ESD PCB Damage Risk: Wear certified anti-static wrist strap during disassembly and installation; bare hand contact with internal switching chips and isolation transformer leads permanently damages power conversion circuits.❗ Loose Terminal Torque Defect: Under-tightened input/output wire terminals create high contact resistance, leading to overheating during continuous full-load operation and triggering persistent fault LED alarms.❗ Live Terminal Wiring Danger: Do not plug/unplug DC input/output wires while the module is energized; DC arc surge will damage internal switching semiconductors.
4-Step DIN Rail Module Replacement Guide
- Pre-install Preparation: Lock out and tag out the station DC auxiliary power supply feeding the RXTUG 22H module, wear ESD wrist strap, photograph DC input wiring and 24 VDC output wiring connected to COMBIFLEX relay terminals.
- Removal Operation: Loosen all input/output terminal wire screws, release the DIN rail mounting clip, detach the old RXTUG 22H converter from the cabinet DIN rail.
- Installation & Wiring: Clip the new RXTUG 22H 1MRK000592-A module onto the original DIN rail, replicate station DC input polarity and 24 VDC output load wiring strictly following photographed sequence, tighten all terminal screws to standard ABB torque values.
- Power-on Commissioning Test: Restore station DC auxiliary power, observe front green RUN LED light steady on; measure output terminal voltage to confirm stable 24 VDC without fluctuation; connect all downstream COMBIFLEX relays and verify all relays boot normally with no persistent power fault alarms on DCS/SCADA system.
FAQ
Q: What is the core function difference between RXTUG 22H and ordinary small 24V DC power supplies?A: Standard industrial 24V power supplies only support fixed narrow input voltage ranges (e.g., only 220 VDC). RXTUG 22H accepts the full 24–250 VDC substation DC bus range and adds critical galvanic isolation between high-voltage station DC and sensitive relay measuring circuits, which ordinary non-isolated power supplies cannot provide. It is purpose-calibrated for COMBIFLEX relay low-noise logic power requirements.
Q: Can multiple COMBIFLEX relays share one RXTUG 22H output?A: Yes, maximum 3–4 standard COMBIFLEX relays (RXIDK/RXEDK/RXPPK series) can be connected to one RXTUG 22H output without exceeding the 22 W rated power limit. Adding more relays will trigger overload protection and cut off power.
Q: Can RXTUG 22H be hot-swapped with station DC power energized?A: Strictly prohibited. The module connects directly to live high-voltage station DC bus circuits; disassembly under energized conditions will generate severe DC arc flash and permanently damage internal power conversion hardware. Full auxiliary DC power lockout is mandatory before replacement.
Q: What warranty applies to stocked RXTUG 22H 1MRK000592-A modules?A: Factory-new original power converters carry 12-month official ABB manufacturer warranty covering isolated DC-DC conversion circuits, protection logic and terminal insulation. Bench-tested surplus modules provide 6-month functional warranty; damage caused by reverse polarity miswiring, output short-circuit overload or ungrounded ESD handling voids all warranty terms.
Q: Has ABB discontinued RXTUG 22H production?A: No formal EOL notice issued; RXTUG 22H remains standard supply for conventional COMBIFLEX relay panel renovation projects. Modern digital substation IEDs (REF615/RET670) integrate built-in internal power supplies and no longer require separate RXTUG auxiliary converters.
Q: What typical faults indicate a defective RXTUG 22H module?A: Common failure symptoms: Front RUN LED flashes continuously (protection lockout), downstream COMBIFLEX relays fail to boot up, unstable fluctuating 24 VDC output voltage, overheating converter housing during normal load operation, permanent output power loss after station DC power restoration.
