Description

The ABB 086407-502 is a redundant-capable,high-reliability 24 V DC power supply module designed specifically for the ABB AC 800M programmable automation controller(PAC)within the System 800xA distributed control system(DCS)architecture.Engineered for mission-critical applications in power generation,oil&gas,chemicals,and water treatment,this power supply delivers stable,filtered DC output to CPU,communication,and I/O modules—even under harsh electrical conditions.With support for N+1 redundancy,hot-swap capability,and built-in diagnostics,the 086407-502 ensures continuous operation and meets stringent functional safety requirements up to IEC 61508 SIL 3 when deployed in certified safety configurations.

Application Scenarios

At a nuclear power plant in Sweden,the reactor protection system relies on redundant ABB AC 800M PM866 controllers powered by paired 086407-502 modules.During a routine grid disturbance that caused a momentary brownout,one power supply temporarily dropped below nominal voltage.Thanks to the active current-sharing redundancy,the second unit instantly compensated—keeping all safety logic running without interruption.Simultaneously,the integrated diagnostics logged the event and alerted maintenance via the 800xA operator station,enabling proactive replacement during the next refueling outage.The 086407-502 thus played a silent but vital role in maintaining both safety integrity and regulatory compliance.

Parameter

Main Parameters Value/Description

Product Model 086407-502

Manufacturer ABB Ltd.(Process Automation/now part of Hitachi Energy portfolio)

Product Category Redundant Power Supply Module for AC 800M Controller System

Compatible Systems ABB AC 800M(PM851,PM856,PM860,PM864,PM866),System 800xA DCS

Output Voltage 24 V DC(regulated)

Output Current 10 A continuous(max 12 A for short duration)

Input Voltage 85–264 V AC(47–63 Hz)or 100–370 V DC(universal input)

Efficiency>89%at full load

Redundancy Supports parallel connection with identical units for N+1 redundancy

Hot-Swap Yes–can be replaced while system is powered and operational

Protection Features Overvoltage,overcurrent,short-circuit,thermal shutdown

Diagnostic Interfaces LED indicators(OK,DC OK,Fault);digital status via backplane to CPU

Isolation Reinforced insulation,3 kV AC input-to-output isolation

Mounting Slide-in module for AC 800M rail-mounted chassis(e.g.,TK817B baseplate)

Certifications CE,UL 61010-1,cULus,IEC 61508 SIL 3(in safety-configured systems),RoHS

Operating Temperature 0°C to+60°C(derating above 50°C)

Dimensions Standard AC 800M module width(~40 mm),height~180 mm

Note:Requires compatible AC 080 backplane(e.g.,TK817B)and proper ventilation in the controller cabinet.

Technical Principles and Innovative Values

Innovation Point 1:True Active Current Sharing for Seamless Redundancy

Unlike passive diode-based redundancy,the 086407-502 uses active load-balancing circuitry—ensuring both supplies share current equally,reducing thermal stress and extending service life.

Innovation Point 2:Integrated Health Monitoring via Backplane Communication

The module reports real-time status(input voltage,output current,temperature)directly to the AC 800M CPU—enabling predictive maintenance and eliminating manual PSU checks.

Innovation Point 3:Universal Input for Global Deployment

Accepts both AC and DC mains worldwide—from 110 V AC in North America to 220 V AC in Europe or 125 V DC in substations—simplifying spares logistics.

Innovation Point 4:Electromagnetic Hardening for Substation Environments

Designed to withstand IEC 61000-4-4(EFT)and IEC 61000-4-5(surge)levels common in high-voltage switchyards—critical for utility-grade reliability.

Application Cases and Industry Value

In a Middle Eastern desalination plant,dual 086407-502 units power an AC 800M system controlling high-pressure reverse osmosis pumps.When a sandstorm caused a 200 ms power flicker,the redundant PSUs maintained clean 24 V output—preventing a cascade shutdown that would have cost$500K/day in lost water production.In another case,a European chemical facility used the 086407-502’s diagnostic data to trend PSU aging over 5 years,replacing units before failure during planned outages—achieving 99.999%controller availability.These examples highlight how power isn’t just“on/off”—it’s a strategic layer of system resilience.

Related Product Combination Solutions

ABB PM866AK01:Primary AC 800M CPU often powered by 086407-502

ABB TK817B:Baseplate/backplane supporting dual redundant power supplies

ABB CI854/CI864:Communication modules requiring stable 24 V from the same PSU rail

ABB AO810/DI810:Analog/digital I/O modules dependent on clean PSU output

ABB System 800xA Engineering Studio:Software environment where PSU diagnostics are visualized

ABB Power Quality Analyzers(e.g.,PQM1000):Used during commissioning to validate PSU performance

Redundant Battery Backup Units(e.g.,ABB PCS100):Extend ride-through during prolonged outages

ABB Cyber Security Manager:Ensures firmware integrity of all system components,including PSU logic

Installation,Maintenance,and Full-Cycle Support

Installation requires mounting the 086407-502 into an AC 800M chassis with proper airflow clearance and connecting AC/DC input wiring per local codes.When used in redundancy,both units must be of the same model and firmware version.Configuration is automatic—the AC 800M CPU detects PSU presence and enables diagnostics without user intervention.

Maintenance best practices include:

Quarterly review of PSU diagnostic logs in 800xA for voltage drift or temperature rise

Annual infrared inspection of input terminals for hot spots

Replacement every 8–10 years as part of lifecycle management(even if functional)

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