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ABB HVC-02B

Product Parameters

Specification Details
Device Type Industrial 2-channel high-voltage load control module
Model Number HVC-02B
Number of Channels 2 (independently controlled)
Power Circuit Input Voltage AC 230/400 V, 50/60 Hz (supports 2-phase/3-phase connection)
Rated Current per Channel 16 A (at ambient temperature ≤40 °C)
Max Power per Channel 3.68 kW (AC 230 V); 6.4 kW (AC 400 V)
Control Signal Input DC 24 V (19.2–30 V wide range), digital (ON/OFF)
Protection Features Short-circuit protection, overload protection, phase-loss protection, 2.5 kV galvanic isolation
Startup Mode Normal (instant); Soft start (0.5–1s, for high inrush current loads)
Diagnostic Output LEDs + PLC digital feedback (PNP type)
Protection Class IP20
Operating Temperature Range -20…+60 °C
Mounting Type 35 mm DIN rail
Dimensions (W×H×D) 45 × 120 × 90 mm
Compatible Controllers ABB AC800M, ABB 800xA DCS, Siemens S7, Schneider Modicon, Rockwell Allen-Bradley
Design Lifetime ≥12 years (when operating at -10…+50 °C)
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Description

ABB HVC-02Bis an industrial-grade high-voltage load control module developed by ABB, designed for switching and regulating high-voltage power circuits (AC 230/400 V) in automated systems. ABB HVC-02B belongs to ABB’s Power Control series of power modules, specializing in high reliability, overload protection, and seamless integration with PLC/DCS systems. It is ideally suited for applications in the energy sector (distribution switchboards), industrial production (electric motors, heaters), and infrastructure (industrial site lighting)—scenarios where safe and precise control of high-voltage loads is critical.

Product Description

ABB HVC-02B is a 2-channel high-voltage load control module, with each channel supporting a rated current of 16 A (maximum single-channel power of 6.4 kW at AC 400 V, total maximum power of 15 kW). It enables independent control of two separate high-voltage loads simultaneously. Its core function is to receive control signals from PLCs (e.g., ABB AC800M, Siemens S7 series) to start or stop high-voltage devices. For example, in a chemical plant, ABB HVC-02B can separately control a reactor heater (10 A) and a cooling fan (5 A), with both loads operating independently without interference.

 

A key advantage of ABB HVC-02B is its comprehensive circuit protection mechanism. Each channel is equipped with an independent thermistor fuse, plus electronic protection against short circuits, overloads, and phase loss. If the load current exceeds the 16 A rating or a short circuit occurs, ABB HVC-02B quickly cuts off the faulty channel within 0.1–0.3 seconds, preventing damage to the load and the module itself. In industrial site lighting control, for instance, if one lighting circuit shorts out, ABB HVC-02B only shuts down the faulty loop—leaving other lighting areas operational to maintain production continuity.

 

Additionally, ABB HVC-02B includes safety and usability features:

 

  • Galvanic Isolation Between Control and Power Circuits: The module provides 2.5 kV galvanic isolation between low-voltage control signals (DC 24 V from the PLC) and high-voltage power circuits (AC 230/400 V). This prevents high-voltage leakage into the PLC system, protecting the controller’s electronics and ensuring operator safety. In a metallurgical workshop, when ABB HVC-02B controls a rolling mill motor, even if the power circuit malfunctions, the PLC remains unaffected.
  • Real-Time Diagnostics: The front panel features status LEDs for each channel (green = running, red = fault, yellow = warning) and a power LED. ABB HVC-02B also sends diagnostic signals (e.g., channel faults, overload warnings) back to the PLC via a digital output. If a heating load develops abnormal current due to component aging, ABB HVC-02B immediately sends a fault signal to the PLC, triggering an audible alarm to alert maintenance staff.

 

ABB HVC-02B also supports a “soft start” function for loads with high inrush currents (e.g., electric motors, nickel-chromium heaters). It gradually increases current over 0.5–1 seconds during startup, reducing grid stress and avoiding voltage surges that could disrupt other equipment. In a food factory’s pasteurization line, ABB HVC-02B uses soft start to control heating tubes, extending the heating element’s lifespan. The module is also easy to install: it mounts on a standard 35 mm DIN rail, uses screw terminals for wiring, and requires no additional programming—simply connect the PLC’s control signal to activate a channel, simplifying deployment in existing systems.

Product Parameters

Specification Details
Device Type Industrial 2-channel high-voltage load control module
Model Number HVC-02B
Number of Channels 2 (independently controlled)
Power Circuit Input Voltage AC 230/400 V, 50/60 Hz (supports 2-phase/3-phase connection)
Rated Current per Channel 16 A (at ambient temperature ≤40 °C)
Max Power per Channel 3.68 kW (AC 230 V); 6.4 kW (AC 400 V)
Control Signal Input DC 24 V (19.2–30 V wide range), digital (ON/OFF)
Protection Features Short-circuit protection, overload protection, phase-loss protection, 2.5 kV galvanic isolation
Startup Mode Normal (instant); Soft start (0.5–1s, for high inrush current loads)
Diagnostic Output LEDs + PLC digital feedback (PNP type)
Protection Class IP20
Operating Temperature Range -20…+60 °C
Mounting Type 35 mm DIN rail
Dimensions (W×H×D) 45 × 120 × 90 mm
Compatible Controllers ABB AC800M, ABB 800xA DCS, Siemens S7, Schneider Modicon, Rockwell Allen-Bradley
Design Lifetime ≥12 years (when operating at -10…+50 °C)

Advantages and Features

  1. Comprehensive Protection: Triple protection (short-circuit, overload, phase-loss) plus galvanic isolation minimizes risks for high-voltage load operation.
  2. 2-Channel Independent Control: Manages two separate loads simultaneously, saving cabinet space.
  3. Soft Start Function: Reduces inrush current for high-demand loads, protecting the grid and extending equipment lifespan.
  4. Real-Time Diagnostics: Local LEDs and PLC remote feedback enable fast fault identification.
  5. High Usability: DIN rail mounting, plug-and-play PLC integration (no extra programming), and multi-brand controller compatibility lower deployment complexity.

Application Cases by Industry

  • Energy Sector – Industrial Distribution Switchboards
    In an automotive factory’s power distribution system, ABB HVC-02B is integrated into the workshop switchboard to control main lighting (AC 230 V, 8 A) and HVAC fans (AC 400 V, 12 A). The PLC sends automatic control signals based on shifts: lighting and fans activate 8:00–18:00 on workdays and shut down outside these hours. If one lighting circuit shorts, ABB HVC-02B only cuts the faulty loop—keeping fans running to maintain workshop comfort.
  • Industrial Production – Metallurgical Rolling Mills
    In a steel mill’s rolling line, ABB HVC-02B controls a billet conveyor motor (AC 400 V, 15 A) and roll heating device (AC 400 V, 10 A). Soft start is enabled for the motor, gradually ramping up current over 0.8 seconds to avoid inrush damage. If the motor overloads due to billet jamming, ABB HVC-02B cuts power within 0.2 seconds and sends an overload signal to the PLC, triggering an emergency stop to prevent motor burnout or mechanical damage.
  • Food Processing – Pasteurization Lines
    In a dairy’s pasteurization line, ABB HVC-02B controls sterilization tank heating tubes (AC 230 V, 14 A) and conveyor belt motors (AC 230 V, 5 A). The PLC adjusts heating tube operation based on temperature sensor data: when milk reaches 85 °C, it sends a signal to ABB HVC-02B to stop heating. Soft start protects heating tubes from inrush current, while maintenance staff monitor module status remotely via the PLC—reducing on-site inspections.

Comparison with Competitors

Comparison Dimension ABB HVC-02B Siemens SIRIUS 3RW30 (Load Control Module) Schneider TeSys K (Contactor Module)
Number of Channels 2 (independent) 1 1
Rated Current per Channel 16 A 16 A 16 A
Soft Start Function Supported (0.5–1s) Supported (0.3–1.5s) Not supported (instant start)
Galvanic Isolation Level 2.5 kV 2 kV 1.5 kV
PLC Diagnostic Feedback Supported (digital signal) Supported (Profinet communication) Not supported (local LEDs only)
Core Advantage 2-channel + soft start + high isolation Siemens ecosystem compatibility, strong communication Low cost, for basic control

 

ABB HVC-02B stands out with its 2-channel design (reducing module count in cabinets), 2.5 kV high isolation (enhanced safety), and soft start tuning for most industrial loads. By contrast, the Siemens SIRIUS 3RW30 relies on Profinet and is better suited for Siemens PLC ecosystems, while the Schneider TeSys K lacks soft start and PLC diagnostics—limited to simple load control.

Selection Recommendations

ABB HVC-02B is recommended for the following scenarios:

 

  1. Simultaneous Control of Two High-Voltage Loads: e.g., motors + heaters, lighting + fans—its 2-channel design saves space and cost.
  2. High Inrush Current Loads: Electric motors, nickel-chromium heaters—soft start protects the grid and equipment.
  3. High-Safety-Demand Environments: Energy, metallurgy (high-voltage equipment-dense areas)—2.5 kV isolation ensures PLC and operator safety.
  4. Remote Maintenance Needs: Sites requiring PLC-based remote load monitoring—diagnostic feedback reduces on-site inspections.
  5. Multi-Brand PLC Systems: Existing setups using ABB, Siemens, or Schneider controllers—no extra programming required for integration.

 

For Siemens PLCs requiring Profinet, the Siemens SIRIUS 3RW30 is an alternative. For budget-limited single-load basic control, the Schneider TeSys K works. For humid environments (>80% humidity, e.g., food washing areas), install ABB HVC-02B in an IP54+ rated cabinet to prevent moisture damage.

Precautions

  1. Load Parameter Matching: Ensure load current/voltage does not exceed the module’s ratings (16 A per channel, AC 230/400 V)—overloading causes module failure.
  2. 3-Phase Wiring Compliance: For 3-phase loads (e.g., AC 400 V motors), confirm correct phase sequence—wrong wiring may cause motor reversal or damage.
  3. Cabinet Ventilation: Maintain operating temperature within -20…+60 °C. Install cooling fans in cabinets if needed to avoid false protection triggers from overheating.
  4. Terminal Maintenance: Inspect and tighten power circuit terminals every 6 months—oxidized terminals increase resistance and cause overheating.
  5. Power-off Maintenance: Always disconnect high-voltage (AC 230/400 V) and low-voltage (DC 24 V) power before servicing ABB HVC-02B to prevent electric shock or module damage.

  6. HVC-02B

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