🏭Application Scenario

At a European district heating plant,an emergency boiler shutdown sequence required de-energizing gas shutoff valves and activating backup circulation pumps.The control logic resided in an AC 800M PLC,and final actuation was handled by ABB 1TGE102019R4800 modules.During a simulated fault,one relay channel experienced contact arcing due to an inductive pump coil—but thanks to built-in snubber circuits and robust contact materials,the module continued operating without welding or failure.Post-event diagnostics via Control Builder M confirmed all 16 channels responded correctly,validating the module’s suitability for SIL2-rated safety instrumented functions(SIFs).

⚙️Key Technical Parameters

Parameter Specification

ABB Part Number 1TGE102019R4800

Product Name DI810/DO810 Relay Output Module(Note:Often referenced under DO810 family)

Compatible System ABB AC 800M(used in System 800xA,Freelance,or standalone)

Number of Outputs 16 channels

Contact Type Form C(SPDT–Single Pole Double Throw)

Contact Rating 2 A 250 VAC,2 A 30 VDC(resistive load)

Switching Voltage Max 250 VAC/125 VDC

Isolation Galvanic isolation between backplane logic and field side(>2.5 kV)

Relay Type Electromechanical,monostable

Mechanical Life>10 million operations

Electrical Life~100,000 operations at full load

Diagnostics LED per channel(ON/OFF);optional feedback wiring for contact verification

Mounting Plug-in to AC 800M I/O base(e.g.,TB810 terminal base)

Hot-Swap Support Yes(with proper system configuration)

Operating Temp 0°C to+60°C

Certifications CE,UL,CSA,IEC 61508(when used in certified SIF architecture),ATEX(optional variants)

🔍Note:This module is often paired with the TB810 terminal base(part no.1TGE102020R0100),which provides screw terminals and optional fuse protection.

💡Technical Advantages&Innovations

True Physical Disconnection:Unlike SSRs,relays provide air-gap isolation—critical for maintenance safety and compliance with lockout/tagout(LOTO).

Mixed Load Compatibility:Drives AC solenoids,DC indicator lamps,and low-power contactor coils from the same module.

Fail-Safe Design:Relays default to a known state(typically”de-energized=safe”)during power loss or controller fault.

Diagnostic Integration:Status visible in Control Builder M and 800xA Operations,enabling predictive maintenance.

Robust Arc Suppression:Internal RC networks protect contacts from inductive kickback—extending service life in motor/pump control.

🔄Related Products&System Integration

ABB TB810(1TGE102020R0100):Terminal base with removable wiring—enables fast module replacement.

ABB AC 800M CPU(e.g.,PM864,PM866):Main controller that communicates with the 1TGE102019R4800 via Profibus or internal bus.

ABB Control Builder M:Engineering tool for logic programming,I/O mapping,and online diagnostics.

ABB DO820(1TGE102021R0000):Higher-density or solid-state alternative(16-channel transistor output).

ABB DI810(1TGE102018R4800):Companion 16-channel digital input module with similar form factor.

ABB 800xA System:Full DCS integration for alarm management,trending,and asset monitoring.

🔧Installation&Maintenance Guidance

Installation:Insert into compatible I/O base(e.g.,TB810)in an AC 800M rack.Ensure proper keying and secure latching.

Wiring:Use stranded 0.5–2.5 mm²wires with ferrules;torque terminals to 0.6 Nm.

Maintenance:No calibration needed.Monitor LED indicators for output status.Replace if contact resistance exceeds 100 mΩor mechanical chatter occurs.

Spare Strategy:Keep 1–2 spares per critical system—relay wear is predictable but irreversible.

✅Support&Warranty

We supply only genuine ABB 1TGE102019R4800 modules,sourced from ABB-authorized channels or factory-sealed surplus inventory.Each unit undergoes:

Functional output test(energize/de-energize all 16 relays)

Contact resistance measurement

Backplane communication validation

Backed by a 12-month warranty and supported by engineers certified in ABB 800xA and AC 800M systems.

📞Need help integrating or replacing your ABB I/O?

Contact us for cross-reference support,lifecycle status(this module is still active as of 2025),or migration planning to newer platforms like AC 900F or Ability™System 800xA Gen 6.