SENSYCON 22-06-61 Asea Boveri 22/06-61

( Brand: Sensycon ), ( Manufacturer Part Number: 22/06-61 ), ( Part Type: Boveri )

Review SENSYCON 22/06-61 Asea Brown Boveri Used

The **Sensycon 22/06-61** from ASEA Brown Boveri (now part of ABB) is a high-performance, analog-style **electronic current transformer (CT) relay**, specifically designed for protective relaying applications in medium-voltage electrical distribution systems. This device is engineered to provide precise and reliable monitoring of fault currents, ensuring the integrity of power networks by detecting and isolating faults with minimal delay. The **22/06-61** operates on the fundamental principle of current differential protection, making it ideal for applications where accurate phase and magnitude comparison of currents is critical, such as in busbar protection, feeder protection, or transformer differential schemes. Its robust construction and modular design allow for seamless integration into existing protection systems, offering flexibility in configuration and scalability for expanding networks.

At its core, the **Sensycon 22/06-61** features a **highly sensitive current measurement system**, capable of detecting even the smallest asymmetrical or transient currents that could indicate incipient faults. The relay employs a **magnetic amplifier or solid-state circuitry** (depending on the specific variant) to amplify and process the input signals, ensuring fast and accurate tripping decisions. Its **adjustable threshold settings** allow engineers to fine-tune sensitivity levels, balancing between false tripping and reliable fault detection, which is particularly valuable in systems with varying load profiles or harmonic distortions. The device also incorporates **time-delay functions**, enabling graded tripping to coordinate with other protective devices in the network, thus preventing cascading outages.

One of the standout features of the **Sensycon 22/06-61** is its **versatile input and output interfaces**, which support a range of signaling and control options. It can be configured for direct connection to current transformers (CTs) with standard ratios, making it compatible with a wide array of primary system voltages and current levels. The relay also provides **auxiliary contacts** for external signaling, alarming, or interlocking, enhancing its functionality in complex protection schemes. Additionally, its **compact and rugged design** ensures durability in harsh industrial environments, where exposure to temperature fluctuations, vibration, or electromagnetic interference is common.

For maintenance and diagnostic purposes, the **Sensycon 22/06-61** often includes **built-in test and calibration features**, allowing operators to verify its performance without disrupting the system. Some variants may also support **remote monitoring and communication protocols**, enabling integration with SCADA or protection management systems for centralized oversight. This relay is particularly well-suited for applications in **substations, industrial plants, and critical infrastructure**, where the reliability of protection systems is paramount. Whether deployed in a traditional analog protection setup or as part of a modern digital protection architecture, the **Sensycon 22/06-61** delivers dependable performance, ensuring the safety and continuity of electrical power distribution.

The **Siemens Sensycon 22/06-61 (ASEA Brown Boveri 220661)** is a legacy **electronic load controller (ELC)** used primarily in industrial and commercial applications for controlling electric motors, heating elements, or other high-power loads. Below is a detailed analysis of its pros and cons, followed by a conclusion and recommendation.

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### **Pros of the Siemens Sensycon 22/06-61**

1. **Reliability and Durability**

The Sensycon 22/06-61 is a well-established model from ASEA Brown Boveri (now Siemens), a company known for robust industrial automation components. These units were designed for harsh environments and continuous operation, making them durable if maintained properly.

2. **Proven Performance**

The unit has been in use for decades, which means its control algorithms and hardware have been tested in various applications. It is capable of handling **soft starts, reversing, and multi-step control** of motors and loads, making it versatile for industrial processes.

3. **Compatibility with Legacy Systems**

If your facility already uses Siemens or ASEA/BB equipment, this controller integrates seamlessly with existing wiring, control panels, and PLCs. It avoids the need for costly retrofitting or compatibility issues.

4. **Manual and Automatic Control Options**

The unit supports both **manual and automatic operation**, allowing for flexibility in control strategies. It can be wired for **start/stop, jogging, and speed control** depending on the application.

5. **Overload and Protection Features**

It includes built-in **overload protection, short-circuit protection, and thermal monitoring**, reducing the risk of damage to connected equipment. Some models also feature **delayed start** to prevent inrush current issues.

6. **Modular and Expandable**

The Sensycon series was designed with modularity in mind, allowing for the addition of **auxiliary relays, timers, or communication modules** (if retrofitted) to extend functionality.

7. **Lower Cost Compared to Modern Alternatives**

Since this is an older model, it is often **cheaper to purchase and repair** than newer PLC-based controllers. Replacement parts (relays, contactors, etc.) may also be more affordable.

8. **No Dependency on Software or Programming**

Unlike modern PLCs, the Sensycon 22/06-61 does not require **programming software or firmware updates**, reducing maintenance complexity.

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### **Cons of the Siemens Sensycon 22/06-61**

1. **Outdated Technology**

The unit relies on **relay-based logic and analog control**, which is less precise and flexible compared to modern **PLCs (Programmable Logic Controllers) or VFD (Variable Frequency Drive) systems**. This limits advanced control features like **PID regulation, energy savings, or remote monitoring**.

2. **Limited Communication and Integration**

The Sensycon 22/06-61 lacks **modern communication protocols** (Ethernet, Modbus, Profibus, etc.). Integration with SCADA systems or IoT platforms is difficult without additional converters or interfaces.

3. **Higher Maintenance Requirements**

- **Relay wear and tear**: Mechanical relays degrade over time, requiring **periodic inspection and replacement**.

- **No self-diagnostics**: Unlike modern controllers, it does not provide **fault logging or predictive maintenance alerts**.

- **Manual adjustments**: Parameters (like timing or current limits) often require **physical wiring changes** rather than software adjustments.

4. **Lower Energy Efficiency**

Traditional **star-delta starters or across-the-line starters** (common in older ELCs) are **less energy-efficient** than modern **VFDs**, which provide **soft starts, variable speed control, and energy savings**.

5. **Limited Scalability**

Expanding functionality (e.g., adding more control steps or sensors) may require **additional hardware** rather than software updates, increasing complexity.

6. **Parts Availability Challenges**

While parts may still be available, **long-term reliability depends on sourcing components** from Siemens or third-party suppliers. Some specialized relays or contactors may become obsolete over time.

7. **No Built-in Safety Features**

Modern controllers often include **safety PLCs, emergency stop integration, and fail-safe modes**, which are absent in this unit. This could be a concern in **high-risk industrial environments**.

8. **Training and Expertise Dependency**

Operating and troubleshooting the Sensycon 22/06-61 requires **knowledge of relay logic and analog control**, which is less common among newer technicians familiar with PLC programming.

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### **Conclusion**

The **Siemens Sensycon 22/06-61 (ASEA BB 220661)** remains a **reliable, cost-effective solution** for applications where **simplicity, durability, and legacy compatibility** are prioritized. It excels in **basic motor control, overload protection, and manual/automatic operation** without the need for complex programming.

However, **modern industrial applications** (especially those requiring **energy efficiency, remote monitoring, or advanced control**) would benefit far more from **PLC-based systems or VFD solutions**. If your facility is **already using this controller successfully** and does not require upgrades, it can continue to operate effectively with **proper maintenance**.

For **new installations or retrofits**, a **modern PLC (e.g., Siemens S7-1200, Allen-Bradley Micro800) or a VFD (e.g., Siemens Sinamics, ABB ACS880)** would offer **superior flexibility, energy savings, and integration capabilities**.

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### **Recommendation**

- Your system is **already operational and reliable**.

- You **do not need advanced control features**.

- **Budget constraints** make replacement impractical.

- **Legacy compatibility** is critical (e.g., in a system with no other alternatives).

- A **modern PLC (e.g., Siemens S7-1200, Rockwell Automation 1769)** if you need **programmable logic, communication, and scalability**.

- A **VFD (Variable Frequency Drive)** if you require **energy savings, soft start, and speed control**.

- A **hybrid solution** (e.g., keeping the Sensycon for basic control while adding a PLC for advanced functions) if a full replacement is not feasible immediately.

- **Regularly inspect relays, contactors, and wiring** for wear.

- **Test overload protection** periodically to ensure functionality.

- **Document wiring and settings** to simplify troubleshooting.

- **Consider a backup controller** if critical operations depend solely on this unit.

If the unit is **failing frequently or causing downtime**, the **cost of repairs may outweigh the benefits**, making an upgrade a more economical long-term solution.

Details:

All products are guaranteed to be working but may show signs of use if purchasing a used product. Call to use a shipping service other than the ones listed. Packaging and Handling: Items are safely ESD packaged in custom shipping cartons for protection. Sells new and surplus product develops channels to purchase such.

specifications generapneumati:

• brand: Sensycon
• mpn: 22/06-61
• part type: Boveri

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