ABB 5SHX2645L0004 3BHL000389P01014

Description

Product Description

Product Parameters

• Brand & Model: ABB, 5SHX2645L0004 3BHL000389P01014
• Device Type: Dual-Model Ultra-Heavy-Duty Power Control & Safety Integration Module for PLC Automation Systems
• Power Supply: 400–690V AC 3-phase (power circuit), 24V DC (control & safety circuit), ±15% voltage tolerance
• Safety Rating: IEC 61508 SIL 3, EN ISO 13849-1 PL e
• Power Switching Capacity: 850A (continuous), 1700A (peak, 5s)
• Control Modes: Voltage vector control, scalar control, torque control, profile speed control, position control (configurable via PLC)
• I/O Channels: 28 safety digital inputs, 22 safety digital outputs, 18 analog inputs (4–20 mA), 16 analog outputs (4–20 mA)
• Protection Functions: Overcurrent/overvoltage/undervoltage protection, overtemperature protection, short-circuit detection, overload protection, phase loss protection, ground fault protection, arc fault detection, surge protection, reverse polarity protection
• Communication Protocols: Profinet IRT, Ethernet/IP, Modbus TCP, Safety over EtherCAT (FSoE), ABB proprietary high-speed power bus
• Communication Ports: 4 x Gigabit Ethernet ports, 1 x RS-485 serial port, 1 x USB configuration port
• Operating Temperature: -40°C to +95°C
• Protection Rating: IP21 (base unit), IP55 (with optional protective enclosure)
• Dimensions (W × D × H): 185 mm × 235 mm × 315 mm
• Weight: 10.2 kg
• Compatible PLC Systems: ABB AC 800M, ABB AC 800XA, ABB Freelance 4000, third-party PLCs (Siemens, Rockwell)
• Certifications: CE, UL, CSA, ATEX, IECEx

Advantages and Features

1. Ultra-High Power & SIL 3 Safety Integration: ABB 5SHX2645L0004 3BHL000389P01014 integrates 850A continuous power switching capacity with SIL 3-certified safety logic, eliminating the need for separate power control and safety devices. This all-in-one design reduces system complexity, saves electrical cabinet space, and ensures compliance with strict industrial safety regulations for high-risk applications.
2. Five-Mode Precision Control Flexibility: The module supports five configurable control modes, ranging from high-precision position control for automated manufacturing lines to robust torque control for mining machinery. This versatility allows seamless adaptation to diverse industrial scenarios via simple PLC command adjustments, enhancing cross-application usability.
3. Profinet IRT & FSoE Dual Real-Time Communication: With built-in support for Profinet IRT (≤ 0.3 ms latency) and Safety over EtherCAT, ABB 5SHX2645L0004 3BHL000389P01014 enables synchronized operation of multiple high-power devices and real-time safety status monitoring, critical for complex systems like steelmaking continuous casting lines or large chemical processing plants.
4. Extreme Environmental Durability: Equipped with EMC Class 4 electromagnetic interference protection and an operating temperature range of -40°C to +95°C, ABB 5SHX2645L0004 3BHL000389P01014 maintains reliable performance in harsh environments, including arctic industrial sites, desert-based power plants, and high-vibration heavy machinery workshops.
5. Advanced Diagnostics & Predictive Maintenance: Compatible with ABB’s Automation Builder software, the module offers intuitive parameter configuration, real-time status monitoring, and advanced fault diagnosis. Built-in self-test functions and predictive maintenance alerts proactively identify potential issues, minimizing unplanned downtime and reducing long-term operational costs.

Application Cases in Industry

• Steel & Metal Manufacturing: ABB 5SHX2645L0004 3BHL000389P01014 is widely used in large-scale steel mills to control blast furnace main motors, hot rolling mill drives, and continuous casting equipment. Its 850A continuous power capacity and arc fault protection ensure stable production processes, while SIL 3 safety functions prevent accidents during high-load operations.
• Mining & Mineral Processing: In large-scale mining operations, the module manages the power of super-sized excavator traction motors, long-distance conveyor systems, and crushing equipment. Its rugged design withstands dust, vibration, and extreme temperatures in underground and open-pit mining sites, ensuring uninterrupted material extraction.
• Chemical & Petrochemical Industry: For oil refineries and large chemical plants, ABB 5SHX2645L0004 3BHL000389P01014 controls high-power pump arrays, compressor units, and distillation column drives. Its comprehensive protection functions minimize safety risks associated with hazardous material processing, complying with strict industry regulations.
• Power Generation & Utilities: In thermal, hydropower, and large renewable energy plants, the module controls boiler feed pumps, cooling tower fans, and generator auxiliary systems. Its 850A continuous capacity ensures uninterrupted operation even under peak load conditions, supporting grid stability and reliable energy supply.

Comparison with Competitors

Selection Suggestions

1. Match Ultra-High Power & Safety Needs: ABB 5SHX2645L0004 3BHL000389P01014 is ideal for large-scale industrial projects requiring both extreme current handling and SIL 3 safety compliance, such as steel mills, mining operations, large chemical plants, and utility-scale power generation facilities.
2. Verify Voltage Compatibility: Confirm that your industrial power grid aligns with the module’s 400–690V AC input range to avoid additional voltage conversion and ensure seamless integration with existing infrastructure.
3. Evaluate Environmental Conditions: For applications in extreme temperatures, high-electromagnetic-interference areas, or high-vibration environments, the module’s rugged design and wide operating range offer superior reliability compared to competitors.
4. Check Protocol Support: Ensure your existing PLC system supports Profinet IRT, Ethernet/IP, or FSoE to leverage the module’s real-time control and safety communication capabilities.

Precautions

1. Installation: When installing ABB 5SHX2645L0004 3BHL000389P01014, ensure adequate spacing (minimum 150 mm) from other heat-generating components for proper heat dissipation. Separate high-voltage power cables from control and communication cables to minimize electromagnetic interference, and follow ABB’s strict grounding guidelines.
2. Parameter Tuning: Use ABB’s Automation Builder software for precise parameter configuration, especially for control modes and safety thresholds. Improper tuning can lead to equipment damage, reduced efficiency, or safety hazards in high-power applications.
3. Regular Maintenance: Periodically inspect the module’s terminals for looseness, corrosion, or overheating. Test all protection and safety functions regularly to ensure they operate correctly under fault conditions. Avoid using water or chemical cleaners on the module’s enclosure.
4. Storage: Prior to installation, store ABB 5SHX2645L0004 3BHL000389P01014 in its original packaging in a dry environment with a temperature of 5°C to 35°C and relative humidity ≤ 60%. Protect it from mechanical impact, direct sunlight, and moisture.
5. Firmware Updates: Only update the module’s firmware via ABB’s official software. Unauthorized firmware modifications may compromise performance, invalidate safety certifications, or cause critical system malfunctions.

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