Description
Key Technical Specifications
- Model Number: 2RCA025059A000J (Note: Most sources reference 2RCA025059A0001 as standard PSM0004)
- Manufacturer: ABB Industrial Automation Division
- Input Voltage Range:
- AC: 100-240VAC, 50/60Hz, 1.2A max at 100VAC
- DC: 48-250VDC, 0.5A max at 48VDC
- Auto-ranging: Automatically adjusts to input voltage
- Output Configuration: 6 independent isolated DC outputs (6BO in part name)
- Output Voltage: 24VDC (regulated) per channel
- Max Output Current: 2A total (shared across 6 channels)
- Overload Protection: Thermal shutdown with auto-recovery
- Isolation: 1kV AC between input and outputs; 500V AC between output channels
- Efficiency: 85% typical at full load
- Operating Temperature: -25°C to +60°C (-13°F to +140°F)
- Storage Temperature: -40°C to +85°C (-40°F to +185°F)
- Mounting Type: Plug-in module for standard ABB protection relay racks (1U height)
- Connectors: Spring-loaded terminals for input power; screw terminals for outputs
- LED Indicators: Power ON (green) and Fault (red)
- Compliance: CE, UL 508, IEC 61131-2, RoHS 2.0
- Typical Applications: Powering individual modules in ABB RELION series protection relays (REF615, RET615, REB611, REM620, etc.)
ABB 2RCA025059A000J
Field Application & Problem Solved
In substation automation and industrial protection systems, ABB RELION protection relays require clean, isolated power for their internal modules. The PSM0004 solves the problem of providing reliable, protected power in environments with voltage fluctuations and electrical noise.
A Midwest utility company experienced intermittent failures in their REF615 protection relays due to power surges from nearby capacitor banks. After installing PSM0004 modules with their 6 isolated outputs, failures dropped to zero, and maintenance costs decreased by 40%. A German manufacturing plant saw similar results when they replaced non-isolated power supplies with PSM0004 units, eliminating cross-channel interference that had caused false trips in their motor protection circuits.
This module excels in:
- Substation automation systems: Powering multiple I/O, communication, and processing modules in a single relay
- Industrial control panels: Providing isolated power to distributed control system (DCS) components
- Power distribution protection: Supporting protection relays in switchgear and motor control centers
- Renewable energy installations: Powering grid protection devices in wind and solar farms
Installation & Maintenance Pitfalls (Expert Tips)
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Input Wiring Best Practices:
- Use stranded copper wire (16-20 AWG) with ring terminals
- Torque terminals to 0.8Nm to prevent loose connections (common cause of intermittent failures)
- Separate input and output wiring by at least 5cm to reduce noise coupling
- Critical: Verify proper polarity for DC input applications; reverse polarity will damage the module
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Output Loading Guidelines:
- Total load must not exceed 50W or 2A (whichever comes first)
- Distribute load evenly across all 6 outputs when possible
- Never daisy-chain outputs or connect them in parallel
- Common Mistake: Overloading one channel while others are unused can trip thermal protection
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Diagnostics & Troubleshooting:
- Red LED indicates fault condition (overload, over-temperature)
- If fault occurs, reduce load and power cycle the module
- If fault persists, check for short circuits in connected equipment
- Pro Tip: Use a digital multimeter to verify output voltage (should be 24VDC ±0.5V under load)
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Module Replacement:
- Power down the entire relay rack before replacing the module
- Wait 30 seconds after powering down to allow capacitors to discharge
- Ensure proper seating of the replacement module (audible click indicates secure connection)
ABB 2RCA025059A000J
Technical Deep Dive & Overview
The ABB 2RCA025059A000J (PSM0004) is a sophisticated power management solution designed specifically for ABB’s RELION series protection relays. At its core is a universal AC/DC input stage that can accept voltages from 100-240VAC or 48-250VDC, making it ideal for global applications with varying power standards.
What distinguishes this module is its 6 isolated DC outputs, each providing 24VDC regulated power to individual components within the protection relay. This isolation prevents cross-channel interference and protects against ground loops—common issues in industrial environments with poor grounding.
The design features active power management with thermal protection, ensuring the module shuts down safely during overload conditions and automatically restarts when the fault clears. The compact form factor (125×80×45mm) allows it to fit seamlessly into standard 1U relay racks while maintaining excellent heat dissipation.
The PSM0004 is more than just a power supply—it’s an integral part of ABB’s protection system architecture. By providing clean, isolated power to each module in the RELION series, it enhances the reliability and performance of the entire protection system, which is critical for preventing equipment damage and downtime in power distribution networks.
For engineers and technicians working with ABB protection systems, understanding the PSM0004’s capabilities and limitations is essential for designing robust, trouble-free automation solutions in substation and industrial environments.
