ABB 3BHE039770R0102 PPD539A102

Description

Product Description

The ABB 3BHE039770R0102 PPD539A102 is a critical power system component, specifically a Redundant Power Supply Module for the ABB S800 I/O system used with the AC 800M controller family. This module is not a power supply itself, but a Power Supply Redundancy Module that enables the configuration of two standard S800 power supply modules (like the PPEA121 or PPEA131) in a parallel, N+1 redundant configuration. Its primary function is to manage the load sharing, supervision, and seamless switchover between the two primary power supplies, ensuring continuous, uninterrupted DC power to the S800 I/O station even if one power supply fails. The ABB PPD539A102 monitors the health of both connected power supplies and provides diagnostic signals to the control system. By implementing this module, system availability is significantly increased, which is a crucial requirement for critical processes in industries like oil & gas, chemical, and power generation. The robust design of the ABB 3BHE039770R0102 ensures reliable operation in demanding industrial environments.

Product Parameters

• System Family: ABB AC 800M with S800 I/O.
• Module Type: Power Supply Redundancy Module.
• Function: Enables N+1 redundant operation of two S800 power supply modules.
• Compatible Power Supplies: Designed to work with specific S800 power supply modules (e.g., PPEA121 120W, PPEA131 240W).
• Input Connections: Accepts the DC output from two independent power supply modules.
• Output: Provides a single, redundant DC power output to the S800 I/O baseplate.
• Diagnostics: Features LED indicators for the status of each connected power supply (OK/Fault) and the overall redundancy module status.
• Alarm Contacts: Includes relay contacts that change state upon a power supply failure, which can be wired to a digital input for system alarm.
• Mounting: DIN-rail mounted within the S800 I/O station assembly.
• Wiring: Connects via pre-defined cables or terminal blocks to the power supplies and the baseplate.

Advantages and Features

• High System Availability: Eliminates the power supply as a single point of failure. If one power supply fails, the ABB PPD539A102 automatically and seamlessly transfers the full load to the remaining unit without any interruption to the I/O station.
• Hot-Swap Capability: Allows for the replacement of a failed power supply module while the system remains powered and operational, minimizing process downtime.
• Clear Diagnostic Indication: Visual LEDs provide immediate local indication of which power supply has failed, speeding up maintenance and troubleshooting.
• Integrated Alarm Reporting: The changeover relay contacts provide a direct hardwired signal to the control system, allowing for immediate operator alerting and log entries.
• Optimized for S800 System: Guarantees compatibility and proper load-sharing characteristics when used with ABB’s specified S800 power supplies, ensuring a validated redundant solution.

Application Cases in Application Fields

• Oil & Gas Safety Systems (ESD/F&G): Powers the I/O for an Emergency Shutdown system where loss of I/O power is unacceptable and could lead to a hazardous situation.
• Chemical Process Critical Control: Ensures continuous power to I/O controlling exothermic reactors or toxic chemical handling where a shutdown could cause safety or environmental incidents.
• Power Plant Burner Management: Provides redundant power to I/O racks involved in burner sequencing and flame safety to avoid forced outages.
• Pharmaceutical Batch Processes: Maintains power to I/O during critical batch phases to prevent loss of product and ensure batch integrity.

Comparisons with Competing Products

• Vs. Siemens SITOP PSU8600 Redundancy Module: Siemens offers a similar redundancy module for its modular power supplies. The ABB 3BHE039770R0102 PPD539A102 is specific to the S800 I/O ecosystem, while Siemens’ is for its SITOP PSU8600 system. They are not interchangeable and represent parallel redundant solutions within their respective vendor architectures.
• Vs. Dual Power Supplies with Diode OR-ing Circuits: A custom-built solution using diodes can provide redundancy but lacks the integrated diagnostics, alarm contacts, and managed load sharing of the purpose-built ABB PPD539A102 module.
• Vs. Non-Redundant Single Power Supply: Using a single, larger power supply is cheaper but creates a single point of failure. The redundant configuration with the ABB PPD539A102 is chosen specifically to achieve higher availability targets.

Selection Suggestions and Precautions

1. Use with Identical Power Supplies: The two power supplies used with the ABB PPD539A102 must be identical models (same part number, same wattage rating) to ensure proper load sharing and performance.
2. Correct Wiring and Cabling: Use only the recommended cables or follow the wiring diagram precisely. Incorrect wiring can prevent redundancy from functioning or damage the modules.
3. Total Load Calculation: Even with redundancy, the total current draw of the S800 station must not exceed the rated output of a single power supply. The redundant pair provides backup, not increased capacity.
4. Alarm Integration: For full benefit, wire the alarm relay contacts from the ABB 3BHE039770R0102 to a digital input on the controller and program an appropriate alarm message to alert operators to a PSU failure.
5. Preventive Maintenance: While the system is redundant, a failed power supply should be replaced promptly. The redundancy module allows this to be done during operation, but running indefinitely on a single unit returns the system to a non-redundant state.