ABB 1SAZ421201R1003 TA200DU-135 Thermal Overload Relay 100-135A
ABB 1SAZ421201R1003 Overview
ABB 1SAZ421201R1003 is the catalog number for the TA200DU-135 thermal overload relay.
The device belongs to ABB’s TA200DU family of electromechanical motor protection components
and is designed for use in contactor-based motor control systems. It provides protection
against motor overload and phase failure while integrating directly with compatible ABB
contactors.
The TA200DU-135 has a rated operational current of 135 A and an adjustable setting range
from 100 to 135 A. Its three-pole construction provides protection for three phases in an
applicable motor circuit. The relay uses trip class 10A and includes functions such as
temperature compensation, trip indication, selectable automatic or manual reset, and a
trip-free mechanism.
The complete ABB identification is 1SAZ421201R1003, while TA200DU-135 identifies the
corresponding product type and current range. These identifiers are useful for technical
documentation, equipment parts lists, motor starter configuration and maintenance records.
TA200DU-135 Thermal Overload Relay
The TA200DU-135 is a thermal overload relay designed to protect motors against excessive
current conditions. It operates as part of a motor starter assembly and is normally connected
directly to the associated contactor. The relay monitors the motor circuit and provides a
protection response when an overload condition reaches the specified operating characteristics.
Thermal overload protection is an important part of motor control because excessive current
can produce additional thermal stress in motor windings. The overload relay provides a
controlled protection function that works together with the contactor and other components
of the motor starter.
ABB identifies the TA200DU-135 as an electromechanical protection device for the main circuit.
Its design combines current adjustment, thermal protection characteristics and auxiliary
contacts in a compact component intended for industrial motor control applications.
100-135 A Adjustable Setting Range
One of the main characteristics of ABB 1SAZ421201R1003 is its 100-135 A adjustable setting
range. This adjustment allows the overload relay to be configured according to the rated
current requirements of the protected motor within the permitted range.
The current setting should be selected according to the motor nameplate data, system design
and applicable motor protection requirements. It should not simply be set to the maximum
available value. Correct adjustment helps coordinate the thermal protection function with the
operating characteristics of the motor.
The 100-135 A range places the TA200DU-135 within the higher-current section of the TA200DU
product family. Other TA200DU variants provide different adjustment ranges, making the complete
product identification important when selecting a relay for a specific motor starter.
135 A Rated Operational Current
ABB specifies a rated operational current of 135 A for the TA200DU-135. This rating represents
an important reference when evaluating the relay for an industrial motor control circuit.
The relay is also specified with an AC-3 rated operational current of 135 A. AC-3 is an important
utilization category for motor switching applications and provides a reference for evaluating
the component within the associated motor control architecture.
When designing a motor starter, the overload relay rating should be considered together with the
contactor rating, motor current, supply voltage, short-circuit protection and the requirements
of the complete electrical installation.
Trip Class 10A
ABB 1SAZ421201R1003 is specified with trip class 10A. The trip class defines the thermal response
characteristics of the overload relay and is an important parameter when coordinating motor
protection with motor starting behavior.
Motors can have different starting characteristics depending on their mechanical load, motor
design and application. The selected overload protection characteristics should therefore be
appropriate for the motor and its operating conditions.
The class 10A characteristic identifies the intended response category of the TA200DU-135.
Configuration should follow the motor starter design and the applicable technical requirements
rather than being selected independently of the complete installation.
Temperature Compensation
The TA200DU-135 incorporates temperature compensation. This feature is important for thermal
overload protection because ambient temperature can influence the behavior of thermal protection
components.
ABB specifies an operating ambient air temperature range of approximately -25°C to +55°C,
including compensated operation within the documented range. Storage conditions extend from
approximately -40°C to +70°C.
Temperature compensation helps maintain the intended protection characteristics across the
specified operating environment. The actual installation should nevertheless comply with the
environmental requirements of the relay and the complete motor control equipment.
Auxiliary Contacts
ABB 1SAZ421201R1003 includes one normally closed auxiliary contact and one normally open
auxiliary contact. These auxiliary contacts provide additional switching interfaces for the
motor control circuit.
The normally closed contact can be incorporated into a control circuit so that an overload
condition can influence the operation of the associated contactor. The normally open contact
can be used for signaling or indication functions according to the control system design.
ABB specifies conventional free-air thermal current values of 5 A for both the NC and NO
auxiliary contacts. The actual utilization of these contacts should follow the applicable
voltage, current and utilization-category ratings.
Automatic and Manual Reset
The TA200DU-135 provides selectable automatic or manual reset functionality. This allows the
overload protection behavior to be configured according to the requirements of the motor
control system.
In a manual-reset configuration, the overload condition can require an operator action before
the motor control circuit returns to its normal operating state. Automatic reset provides a
different control behavior where the system design permits automatic recovery.
The appropriate reset mode should be determined by the application and control philosophy.
For equipment where an overload condition requires investigation before restarting the motor,
manual reset can form part of the intended control sequence.
Compatibility with ABB Contactors
ABB technical information identifies the TA200DU-135 as suitable for several ABB contactor
configurations, including A145, A185, AF145, AF185, AF190 and AF205. This compatibility
information is important when selecting the relay for an existing motor starter.
The overload relay is designed to connect directly to compatible block contactors. This
arrangement simplifies the mechanical and electrical integration of the overload relay within
the motor starter assembly.
When replacing a relay, the contactor model should be checked together with the overload relay
part number. A similar current rating does not necessarily mean that two overload relays have
the same mechanical or electrical compatibility.
Electrical Ratings
The TA200DU-135 has a rated insulation voltage of 690 V and a main-circuit rated operational
voltage of up to 690 V AC according to ABB specifications. The auxiliary circuit is specified
for 440 V DC and 500 V AC under the applicable rating conditions.
The relay also has a rated impulse withstand voltage of 6 kV for the main and auxiliary circuit
references specified in the ABB product information. These ratings are important when evaluating
the overload relay within an industrial electrical installation.
Electrical ratings should always be evaluated together with the motor starter, contactor,
short-circuit protection and installation environment. The relay is one component of the complete
protection and control system.
Protection and Motor Control Applications
ABB 1SAZ421201R1003 is intended for motor protection applications where thermal overload
protection is required for a three-phase motor circuit. Its three protected poles allow the
relay to monitor the three phases of an applicable motor circuit.
The TA200DU-135 can be integrated into industrial motor starters used for pumps, fans,
compressors, conveyors, machine tools and other motor-driven equipment where the electrical
characteristics fall within the specified range.
The actual application depends on the motor rating, contactor selection, control circuit,
short-circuit protection and system voltage. Engineering documentation should be used to
confirm the correct configuration before installation.
Installation and Connection
ABB 1SAZ421201R1003 is designed for mounting directly on compatible contactors or by using
an appropriate single mounting arrangement. ABB also identifies a DB200 single mounting kit
as an accessory for the TA200DU family.
The main circuit connection capacity and auxiliary circuit wiring requirements should follow
the applicable ABB specifications. The product documentation specifies main-circuit connection
arrangements and auxiliary terminal requirements for the TA200DU family.
Before installation, the complete relay designation, contactor type, motor current and
electrical system parameters should be verified. Wiring and adjustment should be carried out
according to the applicable electrical drawings and safety procedures.
Part Number Verification
ABB 1SAZ421201R1003 corresponds specifically to the TA200DU-135 thermal overload relay. The
TA200DU family contains several current-range variants, including TA200DU-90, TA200DU-110,
TA200DU-150, TA200DU-175 and TA200DU-200.
Because these models have different current adjustment ranges, using the complete ABB order
code is important when identifying the correct component. For the TA200DU-135, the complete
order code is 1SAZ421201R1003 and the adjustment range is 100-135 A.
Technical purchasing records should retain both the ABB order code and the product type
designation. This provides a clear reference for equipment documentation and helps distinguish
the TA200DU-135 from related overload relay variants.
Technical Summary
ABB 1SAZ421201R1003 is the TA200DU-135 thermal overload relay for industrial motor protection
applications. It has a 100-135 A adjustable setting range, a 135 A rated operational current,
three protected poles and trip class 10A.
The relay provides temperature compensation, one normally closed auxiliary contact, one normally
open auxiliary contact, selectable automatic or manual reset, trip indication, STOP and Test
functions, and a trip-free mechanism. It is designed for direct connection to compatible ABB
block contactors and is suitable for A145, A185, AF145, AF185, AF190 and AF205 contactor
configurations.
When selecting ABB 1SAZ421201R1003 for a motor control system, the complete part number should
be verified together with the 100-135 A setting range, contactor compatibility, motor rated
current, trip class, electrical ratings and installation requirements. These parameters provide
the technical basis for integrating the TA200DU-135 into an applicable ABB motor protection
system.
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