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ABB SD823 Power Supply Module

Product Description

1. Key Specifications

2. Core Functions

2.1 High-Capacity Power Delivery for Dense Loads

• Supports Dense I/O Racks: Powers up to 20 I/O modules (e.g., AI830, DO810) per rack, or a combination of 1× PM851 controller + 4× communication modules (e.g., CI858) + 12× I/O modules—eliminating the need for multiple low-power supplies (reducing cabinet space by 50%).
• Handles Peak Startup Loads: The 30A peak current (30s) accommodates inrush currents from modules with capacitors (e.g., CI858 dual-protocol modules) during system startup, preventing voltage dips that could trigger false DCS faults.
• Ultra-Clean Power: Ripple & noise ≤30mV peak-to-peak (lower than SD822’s 50mV) ensures stable operation of high-precision modules, such as pulse input modules (for encoder feedback in motion control) or analog I/O for low-range sensors (e.g., 0–5V pressure transducers).

2.2 Advanced Redundancy for 24/7 Operations

• N+1/N+2 Redundancy: Up to 4 SD823 modules can be connected in parallel with an ABB RD802 redundancy module (designed for high-current applications). The RD802 balances load across modules (e.g., 2 modules share 20A load, each handling 10A) and switches to remaining units if one or two modules fail—transition time ≤100ms (no impact on DCS operation).
• Hot-Swap with Load Balancing: In redundant configurations, faulty modules can be replaced without powering down the system. The RD802 automatically adjusts load distribution for remaining modules (e.g., 3 modules take over 20A load if 1 fails, each handling ~6.7A), ensuring no single module is overloaded.

2.3 Enhanced Protection & Durability

• Fast Short-Circuit Response: Shuts down in ≤0.5ms (faster than SD822’s 1ms) to limit damage from high-current short circuits (e.g., a shorted DC bus in a CI857 module), reducing risk of wiring overheating or cabinet fires.
• Surge Immunity: IEC 61000-4-5 compliance resists voltage spikes from grid lightning strikes or industrial equipment (e.g., motor starters), a critical feature for outdoor control cabinets (e.g., oil refinery pipeline stations).
• High-Temperature Endurance: The module’s heatsink design and high-grade capacitors (rated for 105°C) enable reliable operation at +70°C ambient temperature—ideal for steel mills or desert power plants where cabinet cooling is challenging.

2.4 Status Monitoring & Remote Diagnostics

• LED Indicators:
  • Green "POWER" LED: Illuminates when output is 24V DC ±1% (normal operation).
  • Yellow "LOAD" LED: Flashes to indicate 80%+ load (warns of potential overload).
  • Red "FAULT" LED: Lights for overcurrent, overvoltage, overtemperature, or surge events.
• Digital Diagnostic Output: A dry contact (normally open) can be connected to a DI810 module, triggering SCADA/HMI alarms (e.g., "SD823 #3 Overloaded" or "SD823 #1 Surge Detected") for remote monitoring.
• Load Monitoring: The RD802 redundancy module (when used) transmits real-time load data (e.g., "Total Load: 15A, Module 1: 5A") to the AC 800M controller, enabling predictive maintenance (e.g., adding a module if load exceeds 16A).

3. Core Advantages (vs. SD822 & Competitors)

3.1 Key Standout Benefits

1. Space & Cost Savings: A single SD823 replaces 2× SD822 modules for 20A loads, reducing rack space by 50% and hardware costs by 30%.
2. Precision for Critical Modules: Ultra-low ripple (≤30mV) ensures reliable operation of high-sensitivity components, such as ABB’s DSTX-150 servo drive modules (for motion control) or CI860 HSE interfaces (for Foundation Fieldbus data).
3. Durability in Harsh Conditions: 105°C-rated capacitors and -25°C~+70°C operating range outperform competitors (typically -10°C~+60°C), making it suitable for extreme environments.

4. Typical Applications

4.1 Large-Scale Power Plant DCS

• Use Case: Powers an AC 800M system for a 1000 MW combined-cycle power plant.
• Configuration: 2× SD823 modules (N+1 redundancy with RD802) supply 24V DC to 2× PM851 redundant controllers, 6× CI858 dual-protocol modules (PROFINET/EtherNet/IP), and 30× I/O modules (AI830/DO810) for boiler/turbine control.
• Value: 20A capacity handles the dense load; redundancy ensures no power loss during maintenance, preventing grid stability risks.

4.2 Petrochemical Refinery Reactor Control

• Use Case: Supports a redundant S100 I/O rack for a crude oil distillation unit.
• Configuration: 3× SD823 modules (N+2 redundancy with RD802) power 4× CI855 PROFIBUS modules, 20× DI810 digital input modules (for safety interlocks), and 15× DO810 digital output modules (for valve control).
• Value: Surge protection resists voltage spikes from nearby pump motors; ultra-low ripple ensures accurate pressure/temperature readings from AI830 modules.

4.3 Metallurgical Hot Rolling Mill

• Use Case: Powers a motion control sub-system with ABB DSTX-150 servo drives.
• Configuration: 1× SD823 (standalone) supplies 24V DC to 4× DSTX-150 servo drives (for roll speed control) and 2× CI857 EtherNet/IP modules.
• Value: 30A peak current handles servo drive startup inrush; ≤30mV ripple prevents motion control errors (e.g., roll speed fluctuations).

5. Installation & Operation Precautions

1. Wiring Requirements
   • Use 4.0mm² copper cables for DC output (rated for 20A continuous current) and 2.5mm² cables for AC input (rated for 5.5A max).
   • Torque terminals to 2.0–2.5N·m (over-tightening strips terminals; under-tightening causes overheating in high-current scenarios).
   • Connect the PE terminal to a dedicated ground bar (resistance ≤0.5Ω) to ensure surge protection effectiveness.
2. Redundancy Setup
   • Use only the ABB RD802 redundancy module (not RD801) — RD801 is designed for 10A modules (SD822) and cannot handle 20A loads.
   • Ensure DC output cables from all SD823 modules to the RD802 are equal in length (±5%) to avoid load imbalance.
3. Ventilation & Cooling
   • Mount the module vertically with ≥70mm clearance above/below (more than SD822’s 50mm) to accommodate higher heat generation.
   • For cabinets with multiple SD823 modules, install forced-air cooling (fans) to maintain ambient temperature ≤50°C (critical for +70°C max operation).
4. Genuine Replacement Only
   Counterfeit SD823 modules lack:
   • 105°C-rated capacitors (fail at high temperatures).
   • RD802 compatibility (cause load imbalance).
   • Surge protection (risk of module damage during spikes).
     Verify authenticity via ABB’s official part number lookup tool.
5. Startup & Load Testing
   After installation:
   1. Measure DC output (should be 24V DC ±0.24V).
   2. Apply a test load (e.g., 15A) and confirm "LOAD" LED does not flash (flashing indicates ≥80% load).
   3. Trigger a simulated short circuit (via a test switch) to verify ≤0.5ms shutdown and auto-recovery.

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