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ABB SDCS-FEX-2 Power Supply Circuit Board  

1. Key Parameters

• Product Model: SDCS-FEX-2
• Product Series: ABB SDCS-FEX Power Supply Boards (VFD Internal Control Power, Compatible with ACS600/ACS800 Series Drives)
• Core Function: Converts ABB VFD DC bus voltage to regulated low-voltage DC power; supplies power to drive control circuits (CPU, I/O modules, communication cards); provides overcurrent/overvoltage/over-temperature protection; maintains stable output during DC bus fluctuations
• Electrical Specifications:

  Parameter	Details	Performance Metrics
  Input Power (DC Bus)	- Input Voltage Range: 380V DC ~ 800V DC (compatible with 3-phase 380V AC/480V AC/690V AC drive rectifiers) - Input Current: ≤2A (at 800V DC input, full load) - Input Ripple Tolerance: ≤10% (DC bus ripple, no output deviation)	Works with mainstream ABB VFD DC bus voltages, eliminating the need for voltage-specific models
  Output Power (Regulated DC)	- Main Output: 24V DC ±2% (for control circuits, I/O modules); Rated Current: 5A; Max Power: 120W - Auxiliary Output: 5V DC ±1% (for CPU and communication components); Rated Current: 3A; Max Power: 15W - Output Ripple & Noise: ≤50mVp-p (24V DC); ≤20mVp-p (5V DC) (20MHz bandwidth)	Delivers stable power to 24V I/O modules (e.g., SDCS-CON-3 control board) and 5V sensitive electronics (e.g., drive CPU), ensuring no signal distortion
  Efficiency & Power Loss	- Efficiency: ≥88% (at 50%~100% load, 600V DC input) - Standby Power Consumption: ≤5W (no load on 24V/5V outputs) - Power Dissipation: ≤20W (full load, 600V DC input)	Minimizes energy loss in drive cabinets; low standby power reduces off-hours energy use for drives in standby mode
  Protection Features	- Overcurrent Protection (OCP): 6A (24V output, latching shutdown); 3.6A (5V output, latching shutdown) - Overvoltage Protection (OVP): 28V DC (24V output); 5.6V DC (5V output) (latching shutdown) - Over-Temperature Protection (OTP): ≥105℃ (heatsink temperature, thermal shutdown, auto-recovery when cooled to ≤85℃) - Short-Circuit Protection (SCP): Instantaneous current limiting (24V: ≤8A; 5V: ≤5A), auto-recovery after fault removal	Prevents damage to drive control components (e.g., CPU, I/O modules) from power anomalies; auto-recovery reduces manual intervention
  Regulation Performance	- Line Regulation: ≤0.5% (input DC bus 380V~800V) - Load Regulation: ≤1% (24V output: 0~5A; 5V output: 0~3A) - Transient Response: ≤200μs (for 50% load step change on 24V/5V outputs)	Maintains stable output voltage despite DC bus fluctuations (e.g., 380V~600V during load transients) or variable load (e.g., 1A~5A as I/O modules activate)

• Mechanical Specifications:
  • Housing Material: FR4 glass-epoxy circuit board (UL94 V-0, flame-retardant); Aluminum heatsink (for power component cooling)
  • Dimensions (W×H×D): 120mm × 180mm × 30mm (mounts to drive cabinet internal brackets via 4 M3 screws)
  • Mounting: Fixed installation in ACS600/ACS800 drive control compartments; Requires ≥20mm clearance from adjacent heat sources (e.g., drive IGBT modules)
  • Weight: Approximately 250g
  • Connectors: 1× 2-pin input connector (DC bus +/–); 1× 4-pin output connector (24V+/24V–/5V+/5V–); 1× 2-pin temperature sensor connector (for OTP)
  • LED Indicators:
    • Power (PWR): Green (input power present, outputs normal)
    • Fault (FLT): Red (overcurrent/overvoltage/over-temperature fault)
    • 24V Output (24V): Green (24V output within ±2% range)
    • 5V Output (5V): Green (5V output within ±1% range)
• Environmental Ratings:
  • Operating Temperature Range: -10℃~+70℃ (-14℉~158℉); Derated by 3% per ℃ above 60℃ (up to 70℃)
  • Storage Temperature Range: -40℃~+85℃ (-40℉~185℉)
  • Humidity Tolerance: 5%~95% RH (non-condensing, 40℃; suitable for industrial drive cabinets)
  • Vibration Resistance: 10~500Hz, 1g acceleration (IEC 60068-2-6; No component damage or output deviation)
  • EMC Compliance: EN 61800-3 (industrial environment immunity); EN 55011 (Class A emissions) | Reduces interference with drive control circuits and nearby communication modules |
• Compliance Standards: IEC 61204-3 (industrial power supplies), EN 60947-5-1 (low-voltage switchgear), UL 508C (industrial control safety), CE, RoHS, IEC 61800-5-1 (VFD safety requirements)

2. Key Features

• Wide DC Bus Input Range (380V~800V): Compatible with ABB ACS600/ACS800 drives powered by 3-phase 380V AC, 480V AC, or 690V AC grids—eliminates the need for multiple power supply models for different drive voltage ratings, simplifying inventory management for industrial sites with mixed drive fleets.
• Two Regulated Outputs (24V/5V): Provides dedicated power for both 24V control circuits (I/O modules, relays) and 5V sensitive electronics (drive CPU, communication chips)—avoids voltage cross-talk between high-current 24V loads and low-current 5V components, ensuring stable CPU operation and accurate I/O signal processing.
• High Efficiency (≥88%) & Low Heat Dissipation: Minimizes energy loss and cabinet heat buildup—at full load (24V/5A + 5V/3A), it dissipates only ~20W (vs. 35W for low-efficiency models), reducing the need for additional cabinet cooling fans and extending the lifespan of adjacent heat-sensitive components (e.g., capacitors).
• Comprehensive Protection Mechanisms: Overcurrent, overvoltage, short-circuit, and over-temperature protection safeguard drive control systems—e.g., short-circuit protection on the 24V output prevents damage to I/O modules if wiring is accidentally grounded, while over-temperature protection shuts down the board to avoid component burnout in overheated cabinets.
• Stable Regulation (Line/Load): ≤0.5% line regulation and ≤1% load regulation ensure consistent output—maintains 24V/5V stability even when the DC bus voltage fluctuates (e.g., 380V~600V during motor startup) or load changes (e.g., 1A~5A as I/O modules activate), preventing drive control errors (e.g., false fault triggers).
• Seamless VFD Integration: Designed as a direct replacement for original ACS600/ACS800 power supply boards—uses matching connectors and mounting holes, enabling plug-and-play installation (≤15-minute replacement time) and minimizing drive downtime during maintenance.
• EMC Immunity for Drive Environments: Complies with EN 61800-3 industrial EMC standards—resists electrical noise from drive IGBTs (inverters) and motor cables, avoiding output voltage ripple that could disrupt CPU communication or I/O signal accuracy.

3. Application Fields

• Industrial VFD Control Power (ACS600/ACS800 Drives): Primary application—powering ABB drive control systems:
  • Manufacturing Plant VFDs: Supplies 24V power to I/O modules (e.g., SDCS-I/O-2) and 5V power to the drive CPU in 10kW~2MW ACS800 drives for conveyors, pumps, and extruders; stable regulation ensures no control errors during peak load (e.g., extruder torque spikes), preventing production line stoppages.
  • Mining Drive Systems: Powers control circuits in ACS600 drives for mine hoists and crushers; wide DC bus input (380V~800V) handles grid voltage fluctuations common in remote mining sites, while over-temperature protection withstands high cabinet temperatures (up to 70℃) in unconditioned mines.
• Heavy Machinery Drive Control: Powering control components in large machinery:
  • Steel Rolling Mill Drives: Supplies power to the control board (SDCS-CON-3) and communication modules in ACS800 drives for rolling mill motors; EMC immunity resists noise from high-power motor cables, ensuring stable 5V CPU power and preventing speed control deviations that affect steel strip thickness.
  • Marine Propulsion Drives: Installed in ACS600 marine VFDs; 95% humidity tolerance withstands damp marine environments, while vibration resistance (1g) handles ship motion—maintains reliable power to control circuits, ensuring smooth propulsion control.
• Energy & Utility Drive Systems: Powering VFDs in energy infrastructure:
  • Wind Turbine Converter Drives: Supplies 24V/5V power to the control system of ACS800 converters in wind turbines; wide DC bus input (380V~800V) adapts to variable DC voltage from the turbine generator, while overvoltage protection shields components from voltage spikes during grid faults.
  • Water Treatment Pump Drives: Powers I/O modules and CPU in ACS600 drives for large water pumps; low standby power (≤5W) reduces energy use for pumps in standby mode, while short-circuit protection prevents damage if pump wiring faults occur.
• Material Handling Drive Control: Powering VFDs in logistics and warehousing:
  • Warehouse Conveyor Drives: Supplies power to the control circuits of ACS800 drives for high-speed conveyors; transient response (≤200μs) handles rapid load changes (e.g., sudden package accumulation), maintaining stable 24V power to photoeye sensors and preventing conveyor jams.
  • Airport Baggage Handling Drives: Installed in ACS600 drives for baggage scanner conveyors; overcurrent protection safeguards I/O modules from wiring faults, while stable 5V power ensures reliable communication with the airport’s baggage management system.
•  

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