Description

The ABB GFD563A102 3BHE046836R0102 is a 32-channel digital output(DO)module designed for ABB’s AC 800M distributed control system and S800 I/O platform.It features electromechanical relays capable of directly switching AC and DC loads up to 250 VAC/24 VDC at 2 A per channel,eliminating the need for external interposing relays in many applications.Built for reliability in demanding industrial settings,it supports hot swapping,per-channel diagnostics,and functional safety compliance—making it ideal for critical actuation tasks in power generation,water treatment,and process industries.

Application Scenarios

At a large hydroelectric facility undergoing control system modernization,engineers needed to replace aging solid-state output cards that failed silently during high-inductive load switching—causing uncommanded gate closures.They deployed the ABB GFD563A102 3BHE046836R0102 across turbine guide vane control,auxiliary pump sequencing,and emergency alarm circuits.The module’s electromechanical relays handled direct 230 VAC coil switching for contactors without snubber circuits,while its built-in“relay stuck”and“open coil”diagnostics provided real-time health status to the operator HMI.During a grid disturbance test,all 32 channels operated flawlessly under 10x inrush current.The GFD563A102 not only restored fail-safe actuation but also cut panel space by 40%compared to legacy solutions requiring external relay blocks.

Parameter

Main Parameters Value/Description

Product Model ABB GFD563A102 3BHE046836R0102

Manufacturer ABB(now Hitachi Energy Automation)

Product Category 32-Channel Digital Output(Relay)Module for AC 800M/S800 I/O

Output Type Electromechanical Form C(SPDT)relays,normally de-energized

Switching Capacity 250 VAC/24 VDC,2 A resistive per channel(max 60 W)

Electrical Life>100,000 operations at rated load

Diagnostic Features Relay feedback monitoring,coil open detection,stuck-contact alarm

Update Time≤10 ms typical response from controller command to contact closure

Installation Platform S800 I/O baseplate(e.g.,TB850 3BSE018130R1)in AC 800M systems

Operating Temperature 0°C to+60°C(industrial grade,conformal coating optional)

Safety Certification Compliant with IEC 61508 up to SIL 2(in redundant architectures)

Physical Dimensions Standard S800 single-width module(approx.35 mm wide)

Technical Principles and Innovative Values

True Load Independence:Unlike transistor-based DO modules,the ABB GFD563A102 3BHE046836R0102 uses physical relays—enabling direct switching of mixed AC/DC,inductive,or capacitive loads without external components.

Closed-Loop Feedback Verification:Each relay includes an auxiliary contact that confirms actual mechanical state,allowing the controller to detect welded or failed contacts—a critical feature for safety interlocks.

High Density Without Compromise:Packing 32 fully isolated relay outputs into one S800 slot maximizes cabinet efficiency while maintaining galvanic separation between channels and backplane.

Hot-Swappable in Non-Safety Roles:Can be replaced during operation when used in standard control loops,minimizing downtime in continuous processes like desalination or district heating.

Legacy Migration Simplified:Wiring terminals match older ABB/Bailey DO modules(e.g.,DSAI123),enabling drop-in upgrades without rewiring field devices.

Application Cases and Industry Value

In a municipal wastewater plant in Scandinavia,the sludge dewatering centrifuges were controlled by a mix of PLCs and hardwired relays,leading to frequent misoperations during power sags.The team migrated to an AC 800M system using the ABB GFD563A102 3BHE046836R0102 to directly drive 230 VAC solenoid valves and motor starters.Within six months,the relay feedback diagnostics identified two failing solenoid coils before they caused process upsets.More importantly,during a winter blackout recovery,all 32 outputs re-energized correctly on UPS-backed 24 VDC—proving the module’s robustness under brownout conditions.Maintenance staff now report 60%fewer field callouts for“stuck valve”issues,crediting the GFD563A102’s transparency and reliability.

Related Product Combination Solutions

ABB TB850 3BSE018130R1:Hot-swappable S800 baseplate required for installing the GFD563A102.

ABB FTB850 3BSE018132R1:Field terminal block with fused terminals for safe connection to high-voltage loads.

ABB GFD233A101 3BHE037874R0101:16-channel solid-state DO module for high-speed switching—complementary where relay life is a concern.

ABB DI810 3BSE007928R1:Digital input module often co-deployed to verify field device status via feedback wiring.

ABB PM864 3BSE018161R1:AC 800M CPU that configures logic and monitors diagnostics from the GFD563A102.

ABB Control Builder M:Engineering tool used to assign outputs,enable diagnostics,and integrate into safety logic.

ABB CI854A 3BSE037880R1:Communication module for Profibus or Modbus TCP if remote GFD563A102 stations are needed.

Phoenix Contact REL-MR-24DC/21:External relay sometimes used in parallel for ultra-high-current loads—but often unnecessary thanks to the GFD563A102’s native capacity.

Installation,Maintenance,and Full-Cycle Support

Installing the ABB GFD563A102 3BHE046836R0102 requires mounting it in an S800 baseplate(TB850)and connecting field wiring via the associated terminal block(FTB850).No external power supply is needed for the relays—the module draws coil energy from the S800 backplane.Configuration is performed in Control Builder M,where users define output tags,enable diagnostic alarms(e.g.,“Relay Stuck ON”),and map feedback signals for closed-loop verification.

Maintenance is simplified by front-panel LEDs indicating power and module status,while detailed fault data appears in the controller’s event log.The relays are rated for over 100,000 operations,and the module’s design allows easy visual inspection through the transparent cover.Every unit we supply undergoes full functional testing:32-channel load cycling at 250 VAC,diagnostic injection(e.g.,simulated welded contact),and thermal stress validation.Backed by a 24-month warranty and lifetime access to ABB-certified application engineers,our ABB GFD563A102 3BHE046836R0102 ensures your digital outputs are as dependable as the processes they control.

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