Application Scenarios:
In a hazardous area of an offshore oil platform, a safety instrumented system (SIS) controlling emergency shutdown valves is powered by a fault-tolerant power solution. A single power supply failure cannot compromise the system. Here, dual ABB PP846 3BSE042238R1 modules are deployed in a redundant configuration within the same power supply rack. They share the load, and if the active module fails, the other instantly takes over the full load without interruption. The modules’ hot-swap capability allows technicians to safely replace the faulty unit without tools or shutting down the system, maintaining continuous protection for the platform. The PP846’s wide input voltage range handles unstable platform power, and its NEBS compliance assures operation in harsh conditions. Its integrated diagnostics signal health status to the control system, enabling predictive maintenance. This setup addresses the core pain points of power supply reliability and safety-critical system availability.
Technical Principles and Innovative Values:
Innovation Point 1: True Hot-Swap Redundancy with Current Sharing. The ABB PP846 is designed for parallel operation. Multiple modules can be connected to a common output bus with an advanced active current-sharing circuitry. This ensures that all units share the load evenly, preventing any single module from being overloaded. In a redundant setup, if one module fails, the others automatically and seamlessly pick up the full load with zero interruption to the powered electronics, ensuring system continuity.
Innovation Point 2: Wide-Range Input & High Efficiency. The module accepts a remarkably wide input range (85-264V AC/88-300V DC), making it compatible with virtually any global power source and tolerant of significant voltage sags and surges. Coupled with high conversion efficiency (>85%), it minimizes heat generation and energy loss, which is critical for reducing cooling needs and operational costs in large installations with many power supplies.
Innovation Point 3: Robust Design for Harsh Environments. The PP846 3BSE042238R1 is built to industrial and telecommunications standards, including NEBS Level 3 compliance. Its fanless, convection-cooled design eliminates a common point of failure (the fan) and prevents dust ingress. This robust construction ensures reliable operation in environments with temperature fluctuations, humidity, vibration, and electrical noise, which are typical in industrial and utility settings.
Application Cases and Industry Value:
A combined heat and power (CHP) plant experienced unplanned shutdowns due to failures in the power supplies for its distributed turbine control I/O racks. The old supplies were unreliable and difficult to replace quickly. The plant standardized on a power architecture using the ABB PP846 modules in a 1+1 redundant configuration for each critical I/O cluster. During a severe summer storm that caused voltage spikes, one PP846 in a remote enclosure failed. The redundant partner immediately assumed the full load, preventing any loss of instrumentation or control. An alarm in the control room identified the exact faulty module. A technician performed a hot-swap replacement in under 5 minutes during normal operations. The plant engineer calculated that this event alone prevented an estimated 8-hour production loss worth over $50.000. showcasing the PP846’s direct value in maximizing plant availability and providing a swift, tool-free maintenance response.
Related Product Combination Solutions:
Power Supply Rack (e.g., for PP846): A dedicated subrack that houses multiple PP846 modules, provides the input distribution, and combines the outputs onto a common redundant power bus.
S800 I/O Baseplates (TU810. TU830. TU833): These terminal units house the I/O modules and are directly powered by the 24V DC output from the ABB PP846 system.
AC 800M Controller (e.g., PM866. PM864): The main controller’s processing and communication modules are powered by the clean, reliable 24V DC from the PP846.
SA811: An S800 Analog Input module. It is an example of a field I/O module that relies on the stable power from the PP846 for accurate signal measurement.
Redundancy Module/Diodes: Used in some configurations to ensure proper isolation between redundant PP846 power supplies and prevent back-feeding.
System 800xA Power and Control Solution: The PP846 is a key component in the overall power distribution design for an 800xA node, providing conditioned power to controllers and I/O.
DC/DC Converter Modules: In some installations, the 24V DC from the PP846 may be further converted to other voltage levels (e.g., 5V, 3.3V) for specific electronics using additional converter modules.
Installation, Maintenance, and Full-Cycle Support:
Installation of the ABB PP846 3BSE042238R1 is designed for simplicity and safety. The module slides into its designated slot in the power supply rack and connects via a sturdy blind-mate connector, ensuring correct alignment and connection of both power and signal pins. Mains or DC input wiring is connected to terminal blocks on the rack. Critical steps include verifying the input voltage matches the supply, ensuring proper torque on power terminals, and, for redundant setups, confirming the current-sharing cables are correctly connected between modules. Configuration is minimal, primarily involving setting the unit’s address via DIP switches if required for monitoring.
Maintenance is predictive and straightforward. The module’s front-panel LEDs provide immediate status: AC OK, DC OK, and a red FAIL indicator. The built-in DC OK relay contact can be wired to a controller’s digital input for remote health monitoring. The key maintenance advantage is the hot-swap capability. A failing or failed PP846 can be identified and replaced without powering down the critical load, ensuring 24/7 system availability. We provide genuine, factory-new ABB PP846 power supplies. Our support includes assistance with system power sizing, redundancy scheme design, and troubleshooting, ensuring your control system has the stable, reliable power foundation it requires.
Secure the power foundation of your critical control system. Contact us for genuine ABB power supplies and system design expertise.
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