First Solar’s Andalusia PV plant is one of Europe’s largest, generating enough clean energy to power 180,000 households annually. The plant relies on control relays to manage the integration of PV-generated electricity into the grid, ensuring compliance with Spanish grid codes (RD 1699/2000) and maintaining stable power output. The legacy protection relays presented significant operational challenges:
- Unstable Grid Integration Triggers Disconnections: The legacy relays couldn’t adapt quickly to grid voltage and frequency fluctuations, leading to frequent plant disconnections from the grid. This occurred 12-15 times monthly, resulting in 35-40 hours of lost generation time and €2.1 million in annual revenue losses.
- Inefficient Fault Handling Reduces Energy Yield: The old relays had a slow fault detection time (5-7 seconds) for PV array faults (e.g., panel shading, inverter malfunctions). This caused unnecessary shutdowns of entire PV strings, reducing the plant’s energy yield by 4.2% annually.
- Poor Compliance with Grid Codes: The legacy relays lacked the advanced voltage and frequency ride-through capabilities required by Spanish grid codes, risking non-compliance fines of €350,000 annually. Manual adjustments were required to maintain compliance during grid disturbances.
- Limited Data Analytics for Performance Optimization: The old systems didn’t collect or analyze real-time operational data, making it difficult to identify underperforming PV strings or predict maintenance needs. This increased unplanned maintenance costs by €520,000 annually.
“Grid stability and compliance are critical for the success of large-scale PV plants—any disconnection or non-compliance can lead to significant revenue losses,” said Carlos Ruiz, First Solar Andalusia Plant Manager. “Our legacy relays couldn’t keep up with the dynamic grid conditions and regulatory requirements. We needed a advanced control relay solution that could ensure stable grid integration, efficient fault handling, and compliance with grid codes.”
ABB REC670 Control Relay: Advanced Control for PV Grid Integration
After evaluating solutions from Siemens and Schweitzer Engineering Laboratories (SEL), First Solar selected the ABB REC670 control relay for its advanced grid code compliance features, fast fault handling, real-time data analytics, and rugged design. Key features addressing First Solar’s pain points include:
- Advanced Grid Code Compliance: The ABB REC670 control relay is pre-configured to meet Spanish grid codes (RD 1699/2000) and international standards (IEC 61727), offering enhanced voltage and frequency ride-through capabilities. It automatically adjusts power output during grid disturbances, eliminating disconnections and ensuring compliance.
- Fast Fault Detection & Selective Shutdown: The relay uses advanced digital sensing to detect PV array and inverter faults in <10 milliseconds. It enables selective shutdown of only faulty PV strings, rather than entire arrays, minimizing lost generation time and improving energy yield.
- Real-Time Data Analytics & Remote Monitoring: The REC670 integrates with First Solar’s plant management system via IEC 61850 and OPC UA protocols, collecting real-time data on power output, grid conditions, and relay status. Built-in analytics tools identify underperforming PV strings and predict maintenance needs, reducing unplanned maintenance by 65%.
- Rugged Design for PV Plant Environments: The relay features an IP65-rated enclosure, resistance to extreme temperatures (-40°C to 70°C), and protection against dust and humidity—critical for outdoor PV plant operations. Its solid-state design eliminates moving parts, ensuring reliable performance in harsh weather conditions.
- Flexible Integration with PV Inverters: The REC670 supports seamless integration with all major PV inverter brands, enabling coordinated control of power output and fault response. This enhances overall plant efficiency and simplifies future expansions of the PV plant.
Results: Stable Grid Integration, Higher Energy Yield
Six months after deploying the ABB REC670 control relay, First Solar’s Andalusia PV plant achieved significant operational improvements:
| Metric |
Before ABB REC670 Control Relay |
After ABB REC670 Control Relay |
Improvement |
| Monthly Grid Disconnections |
12-15 |
1-2 |
92% Reduction |
| Annual Lost Generation Time |
35-40 Hours |
5-6 Hours |
86% Reduction |
| Plant Energy Yield |
95.8% |
98.9% |
3.2% Improvement (28% Relative Increase in Yield Efficiency) |
| Annual Unplanned Maintenance Costs |
€520,000 |
€182,000 |
65% Reduction |
| Grid Code Compliance Fines |
€350,000/Year |
€0 |
100% Elimination |
“The ABB REC670 control relay has been a game-changer for our Andalusia PV plant,” Ruiz said. “We’ve achieved near-perfect grid stability, eliminated compliance fines, and increased energy yield—all of which have significantly improved the plant’s profitability. The real-time data analytics have also allowed us to optimize maintenance schedules and identify underperforming assets, further enhancing efficiency.”
Juan Martinez, ABB’s Global Renewable Energy Automation Manager, commented: “Large-scale PV plants require control relays that can handle dynamic grid conditions, ensure regulatory compliance, and optimize energy yield. The ABB REC670 is designed specifically for these challenges, helping renewable energy operators maximize the value of their assets and contribute to a more sustainable energy future.”
First Solar plans to deploy the ABB REC670 control relay across 18 additional PV plants in Europe, North America, and Latin America by 2038, targeting 98% group-wide grid stability and a 30% improvement in energy yield efficiency.
Ludwigshafen, Germany – February 2032 – BASF SE, the world’s leading chemical company, has achieved a 78% reduction in industrial power outages and a 40% decrease in production downtime at its Ludwigshafen chemical complex after deploying the ABB REC670 control relay. The upgrade, completed in Q4 2031, replaced the complex’s outdated industrial control relays, which struggled with slow fault response and poor coordination between critical production systems—leading to costly production disruptions.
