ABB 3BHL000986P7001 redundant DC power supply unit

ABB 3BHL000986P7001 redundant DC power supply unit

Product Overview

ABB 3BHL000986P7001 is a high reliability redundant DC power supply unit designed specifically for industrial critical control systems, belonging to the ABB Industrial Power Solutions series. As the “power center” that ensures stable power supply for core control equipment, its core function is to convert AC input into stable DC output through redundant parallel design of dual or multiple power modules, providing uninterrupted and high-precision DC power for key industrial equipment such as PLC, DCS controller, servo driver, safety relay, etc. At the same time, it has a complete fault monitoring and redundant switching mechanism to ensure uninterrupted power supply in case of single power module failure. It is widely used in industries such as power, chemical, metallurgy, oil and gas, intelligent manufacturing, etc. that require “zero interruption” of power supply reliability.

This power supply unit integrates ABB’s core technologies in power conversion, redundancy control, and industrial reliability design. It adopts a modular architecture and digital control method, and has the characteristics of high output accuracy, strong overload capacity, redundant switching without disturbance, and intuitive fault diagnosis. It can effectively resist risks such as power grid fluctuations and module failures, and is the core component of building a high availability power supply system for industrial control systems.

Core functions and redundant features

1. Core power supply and redundant functions

-N+1 redundancy architecture design: Adopting standard N+1 redundancy configuration (supporting 2-4 power modules in parallel), each power module evenly distributes the load current. When any one module fails, the remaining modules can automatically share all the load (within the overload capacity range), and the switching process is undisturbed (voltage fluctuation ≤ ± 2%), ensuring stable output voltage and uninterrupted power supply, greatly improving the reliability of system power supply.

-High precision DC output control: Equipped with advanced PWM (Pulse Width Modulation) conversion technology and voltage closed-loop regulation algorithm, it stably converts AC 380V/220V input into standard industrial DC voltage such as DC 24V/48V (specific output specifications can be configured), with output voltage accuracy of ≤± 0.5% and ripple factor of ≤ 1%, effectively avoiding voltage fluctuations from interfering with precision control equipment.

-Wide range input and grid adaptability: Supports AC 110V~480V wide range input (compatible with 50/60Hz frequency), can adapt to voltage fluctuations in different regions and scenarios of the grid, and has input overvoltage and undervoltage protection functions. It can maintain stable output even when the grid voltage suddenly changes, reducing the impact of grid disturbances on the power supply system.

-Complete fault protection mechanism: Each power module independently has overcurrent, over temperature, short circuit, and overvoltage protection functions. When an output short circuit or overload is detected, the module can quickly enter the protection state (response time ≤ 10 μ s) to avoid fault propagation; At the same time, the system level has functions such as module fault alarm and output voltage abnormal alarm, ensuring that faults can be detected and handled in a timely manner.

2. Additional practical features

-Digital monitoring and communication capabilities: Equipped with an LCD display panel, it can display the real-time operating status of each module (input voltage, output current, module temperature), system redundancy status, and fault information; Supports mainstream industrial communication protocols such as Modbus RTU, PROFINET, EtherNet/IP, and can seamlessly integrate with the upper monitoring system to achieve remote monitoring, parameter configuration, and fault alarm upload.

-Hot swappable and maintenance convenience: The power module supports hot swappable function, which allows for direct replacement of faulty modules without power outage. The replacement time is ≤ 3 minutes, greatly reducing the recovery time and minimizing production interruption losses caused by maintenance; The module adopts standardized design, with unified wiring and installation standards to improve maintenance efficiency.

-Energy management and energy-saving optimization: Equipped with load adaptive adjustment function, it can dynamically adjust the output current of each module according to the actual load demand of downstream equipment, avoiding inefficient operation of modules under light load conditions; Some models support battery charging and discharging management functions, and can be equipped with external backup battery packs to achieve short-term emergency power supply in case of power outages, further improving power supply continuity.

-Strong environmental adaptability and reliability: The core components adopt industrial grade high weather resistant products, supporting a wide temperature range of -20 ℃~+60 ℃, with a protection level of IP20 (unit body), and have good dust, moisture, and electromagnetic interference resistance, which can adapt to the complex temperature, humidity, and electromagnetic environment of industrial sites.

Key technical parameters

input parameters

Input voltage: AC 110V~480V ± 15%; Frequency: 50/60Hz ± 5%; Power factor: ≥ 0.95 (rated load)

Wide range input, adaptable to different power grid environments, high power factor, low energy consumption

output parameters

Rated output voltage: DC 24V/48V (optional); Output current: 50A for a single module, maximum 200A for the system (4 modules in parallel); Voltage accuracy: ≤± 0.5%; Ripple factor: ≤ 1%

High precision output to meet the power supply needs of devices with different power levels

Redundancy performance

Redundant configuration: N+1 (1-4 modules); Switching time: ≤ 1ms; voltage fluctuation during fault switching: ≤± 2%

Fast switching without disturbance ensures power supply continuity and stability

protection function

Input overvoltage/undervoltage protection, output overcurrent/overvoltage/short circuit protection, module over temperature protection, battery reverse connection protection

Comprehensive protection to prevent equipment damage and the spread of faults

communication interface

1 PROFINET interface; 1 RS485 channel (supporting Modbus RTU); 2-channel dry contact alarm output

Support remote monitoring and fault alarm, easy to integrate into automation systems

Battery Management

Support external 12V/24V lead-acid batteries or lithium batteries; Charging current: adjustable from 0 to 10A

Optional emergency power supply to enhance power supply reliability in extreme situations

working environment

Temperature: -20 ℃~+60 ℃; Humidity: 5%~95% (no condensation); Protection level: IP20

Adapting to complex industrial environments, it needs to be installed inside the control cabinet

Installation method

35mm standard DIN rail installation (module); Cabinet style installation (system unit)

Complies with industrial standardization installation requirements, facilitating system integration and expansion

Typical application scenarios

This redundant DC power supply unit, with its high reliability, disturbance free redundant switching, and flexible adaptability, plays a core role in power supply guarantee in various industrial key scenarios. Typical applications include:

1. Power industry control system: used for supplying power to DCS control systems, PLC control cabinets, and generator excitation control systems in thermal power plants and hydropower plants, ensuring stable operation of control equipment in the event of grid fluctuations or single power supply failures, and avoiding power production interruptions.

2. Petrochemical and oil and gas fields: In the emergency shutdown system (ESD), safety instrument system (SIS), and process control system of refining equipment and oil and gas extraction platforms, redundant power supply is provided for core control modules to ensure the safety and controllability of production processes in flammable and explosive environments.

3. Intelligent manufacturing and automation production line: Provides uninterrupted power supply for key equipment such as industrial robot control cabinets, servo drives, and visual inspection systems, avoiding production line downtime caused by power outages and reducing product scrap and production losses.

4. Metallurgy and steel industry: used for process control stations, furnace temperature control systems, and steel rolling equipment control systems in blast furnace ironmaking and converter steelmaking, to resist workshop power grid fluctuations and load shocks, and ensure stable power supply in high temperature and high dust environments.

5. Data center and industrial communication: Provide redundant power supply for industrial Ethernet switches, data acquisition terminals (RTUs), servers and other equipment to ensure the continuity of industrial data transmission and storage, avoid data loss or communication interruption.

6. Municipal and emergency systems: In the control systems of urban sewage treatment plants, water supply booster stations, and emergency command centers, a backup battery pack is used to achieve dual power supply guarantee of “power grid+battery”, ensuring uninterrupted municipal services and emergency response.

Installation and maintenance precautions

1. Installation specifications

-The power supply unit should be installed in a well ventilated control room or standard cabinet without severe vibration, corrosive gases, or strong electromagnetic radiation, avoiding direct sunlight and rainwater immersion. A heat dissipation space of ≥ 150mm should be reserved around the unit, and the cabinet should be equipped with a heat dissipation fan (if the ambient temperature is ≥ 40 ℃).

-Strictly distinguish between AC input circuits, DC output circuits, and control communication circuits, and use cables of different colors for identification; The AC input should be equipped with an independent circuit breaker (with a capacity of 1.5 times the rated input current), and a fuse or DC circuit breaker should be installed at the DC output terminal to prevent short circuit faults.

-When redundant modules are connected in parallel, current sharing should be achieved through a dedicated current sharing bus to ensure load balancing among all modules; The wiring terminals must be tightened with a torque wrench according to the specified torque (recommended torque values for copper core cables: 1.2N · m for 2.5mm ² and 2.0N · m for 4mm ²) to prevent poor contact and heat generation.

-The system grounding must comply with industrial grounding standards, with AC input grounding, DC output grounding, and protective grounding sharing the same grounding grid, with a grounding resistance of ≤ 4 Ω; When connecting an external battery pack, it is necessary to ensure that the positive and negative terminals of the battery are wired correctly to avoid module damage caused by reverse connection.

2. Maintenance points

-During daily inspections, check the operating status (input voltage, output current, module temperature), redundancy status, and alarm information of each module through the LCD panel or upper monitoring system to ensure that there are no abnormalities; Focus on checking the status of module indicator lights. If there is a malfunction, the light should be checked in a timely manner.

-Clean and maintain the power supply unit every quarter, using compressed air to clean the dust on the module heat sink and cabinet filter, and wiping the panel and wiring terminals with a dry soft cloth to avoid dust accumulation and module overheating; Check the operation of the cooling fan, and replace it promptly if there is any abnormal noise or stoppage.

-Perform a redundancy switching test every six months, manually simulate a single module failure (disconnect module input power), observe whether the remaining modules automatically share the load and whether the output voltage is stable. After the test is completed, restore the module to normal operation to ensure reliable redundancy function.

-Regularly check the status of the external battery pack (if equipped), measure the battery terminal voltage and charging/discharging current, and ensure that the battery capacity meets the emergency power supply requirements; Lead acid batteries are recommended to be replaced every 1-2 years, while lithium batteries should be replaced every 3-5 years to avoid battery aging and emergency power supply failure.

-When the system malfunctions, first locate the faulty module through alarm information. If it is a module failure, hot plugging can be used to replace it; Before replacing the module, it is necessary to confirm that the new module model matches the parameters. After replacement, check the current sharing effect and output stability to ensure that the system returns to normal.