ABB 1MRK002246-BC Migration-Ready CPU Card for Legacy Systems

Overview

ABB 1MRK002246-BC Migration-Ready CPU Card for Legacy Relay Systems

The ABB 1MRK002246-BC is a migration-ready CPU card engineered for direct replacement and retrofit deployment within ABB’s RELION protection relay platform — including the REL670, REC670, and RED670 series. As legacy IED installations age and original CPU modules approach end-of-life, the 1MRK002246-BC provides a verified, drop-in upgrade path that preserves existing wiring, backplane interfaces, and protection logic without requiring full panel redesign.

For maintenance engineers and system integrators managing aging substation automation infrastructure, the 1MRK002246-BC addresses one of the most critical challenges in protection relay lifecycle management: replacing a discontinued CPU card without triggering cascading compatibility failures across the control cabinet. This module is designed to slot into existing RELION chassis with no mechanical modification, maintaining the same terminal layout, communication port positions, and firmware architecture as the original unit.

Before initiating a CPU card swap, field engineers should verify several key parameters. Power supply capacity within the relay panel must be confirmed — the 1MRK002246-BC draws from the same 24–48 VDC auxiliary supply rail used by the original module, and any degraded PSU should be replaced concurrently to avoid post-commissioning instability. The backplane connector alignment must be inspected for pin wear or oxidation, particularly in installations exceeding 10 years of service. Module addressing within the IED configuration tool (PCM600) must be re-mapped if the replacement unit carries a different hardware revision suffix, and all protection function blocks should be re-validated against the original relay setting file.

Communication link continuity is another migration-critical checkpoint. The 1MRK002246-BC supports the same IEC 61850 GOOSE messaging and DNP3/IEC 60870-5-103 protocol stack as its predecessor, but firmware version alignment between the CPU card and the relay’s communication interface modules — such as the ABB LDCM optical fiber communication module — must be confirmed before energization. Mismatched firmware revisions are a common source of post-replacement communication dropouts that can delay recommissioning by hours.

HMI screen mapping and SCADA tag assignments should also be reviewed. In installations where the relay feeds into a MicroSCADA Pro or third-party DCS via IEC 61850, the logical node structure exported from the new CPU card may differ slightly from the archived configuration, requiring a re-import of the IED capability description (ICD) file and re-binding of data objects at the gateway level.

For control cabinet environments where the 1MRK002246-BC is being installed alongside other aging components, a concurrent review of the ABB RBIO analog I/O terminal block modules and binary input/output expansion cards is recommended. These peripheral modules share the same backplane bus and are subject to the same wear cycles as the CPU card. Replacing the CPU in isolation while leaving degraded I/O modules in service is a common cause of intermittent protection misoperation after retrofit.

Signal isolation between the relay’s binary input circuits and field wiring should be verified using the relay’s built-in self-test diagnostics after installation. In high-EMI environments — such as those adjacent to large power transformers or motor drive panels — the ABB RHGS signal conditioning relay or equivalent interposing relay module may be required to maintain signal integrity on binary input channels.

Installation space confirmation is straightforward for standard RELION 670 series chassis, but engineers working with older REL5xx or REC5xx panel cutouts should measure the chassis depth and DIN rail clearance before ordering. The 1MRK002246-BC is dimensioned for the standard RELION 670 form factor and is not mechanically compatible with earlier 500-series housings without an adapter frame.

All units are pre-shipment tested under functional load conditions, with communication ports, binary I/O channels, and analog measurement circuits verified against ABB factory acceptance criteria. Each module ships with a support terms confirmed by quotation covering manufacturing defects and functional failures under normal operating conditions. Stock is maintained for immediate dispatch, supporting both planned maintenance windows and emergency replacement scenarios where relay downtime must be minimized.

Migration Compatibility Table

Retrofit Planning for Existing Automation Systems

A successful 1MRK002246-BC retrofit begins well before the maintenance window opens. The replacement plan should account for the full scope of interdependent components within the relay panel. In a typical RELION 670 protection cabinet, the CPU card interfaces directly with the ABB LDCM optical fiber communication module for station bus connectivity, the RBIO binary I/O expansion module for field contact inputs and trip outputs, and the RAIO analog input module for current and voltage measurement channels. Each of these modules must be confirmed as firmware-compatible with the replacement CPU before the panel is de-energized.

The relay’s 24 VDC auxiliary power supply module — often an ABB PSMV or equivalent — should be load-tested prior to the retrofit. A PSU operating near its rated capacity with a degraded output capacitor bank is a common failure point that surfaces only after a CPU card replacement increases transient current demand during boot-up. Replacing a worn PSU concurrently with the CPU card eliminates this risk and avoids a second maintenance window.

For installations where the relay communicates with a remote RTU or gateway via serial protocol, the ABB COM600 station automation unit or equivalent serial-to-IEC 61850 gateway configuration must be updated to reflect the new IED logical node structure exported by the 1MRK002246-BC. This step is frequently overlooked and is a leading cause of SCADA data loss in the hours following relay recommissioning.

Programming cable and laptop connectivity should be confirmed using the ABB PCM600 engineering tool before the panel is opened. Engineers should archive the existing relay configuration file, protection settings, and disturbance recorder parameters before removing the original CPU card. This archive serves as the rollback baseline if the replacement unit requires firmware adjustment during commissioning.

Downtime Control During System Migration

Minimizing protection relay downtime during a CPU card replacement requires a structured sequence that preserves control continuity and reduces the risk of protection misoperation. The recommended approach is to complete all pre-commissioning verification steps — firmware confirmation, PCM600 configuration upload, communication link testing — on the bench before the relay is taken out of service.

Where possible, the replacement CPU card should be pre-loaded with the archived relay configuration file and protection settings before installation. This reduces in-panel commissioning time to connection verification, self-test execution, and communication link confirmation — a sequence that can typically be completed within a 2–4 hour maintenance window for a single relay.

For substations operating under N-1 contingency constraints, the relay should be replaced during a scheduled outage window with the protected feeder or transformer transferred to an alternate protection scheme. The 1MRK002246-BC’s drop-in mechanical compatibility eliminates the need for panel drilling, cable re-routing, or terminal block rewiring, which are the primary sources of unplanned downtime extension in legacy relay replacement projects.

Post-installation, the relay’s built-in self-monitoring functions — including watchdog output, trip circuit supervision, and binary input status — should be verified against the original relay’s event log to confirm that all protection functions have been restored to their pre-replacement state. A staged secondary injection test is recommended before the relay is returned to service in critical protection applications.

Retrofit Support FAQ

Q: Is the 1MRK002246-BC a direct drop-in replacement for the original ABB REL670 / REC670 CPU card?
A: Yes. The 1MRK002246-BC is mechanically and electrically compatible with the standard RELION 670 chassis backplane. No panel modification is required. Firmware version alignment should be confirmed using ABB PCM600 before installation.

Q: What pre-shipment testing is performed on each unit?
A: Every 1MRK002246-BC undergoes functional load testing covering power-up sequencing, binary I/O channel verification, analog measurement circuit calibration, and communication port connectivity. Test records are available upon request.

Q: How is compatibility with existing protection settings and HMI configurations verified?
A: The module supports the same IED capability description (ICD) file structure as the original unit. Existing PCM600 configuration files can be uploaded directly. For SCADA-connected installations, the ICD file should be re-imported at the gateway level to confirm logical node binding.

Q: What support terms and long-term supply support is available?
A: Each unit carries a support terms confirmed by quotation covering manufacturing defects and functional failures under normal operating conditions. Stock is maintained for immediate dispatch, and long-term supply continuity is supported for planned maintenance programs and emergency replacement requirements.

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ABB
ABB

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1MRK002246-BC
Legacy Series

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PLCs & Controllers

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