ABB SD832 3BSC610065R1 Power Supply Unit

The SD832 is a high-performance 24V DC power module designed specifically for industrial automation and control systems, serving as a core power supply component within the ABB AC 800M controller hardware platform. As a member of the SD83x series power supply units, the SD832 is widely used in process control, discrete manufacturing, High Integrity (HI) systems, and various industrial applications requiring stable, clean DC power, thanks to its compact design, high reliability, compliance with multiple international safety standards, and ease of installation and maintenance.

Within the ABB AC 800M controller system, the Power Supply Unit (PSU) is fundamental to ensuring the stable operation of the entire controller, communication interface modules, CEX-Bus expansion units, and some I/O modules. As a power supply with a rated output of 5A, the SD832 provides the core 24V DC power for medium-load scale AC 800M systems in both single and redundant configurations.

• In Single Configuration: The SD832 can provide stable power for components including PM8xx series processor units, multiple CEX-Bus communication interfaces (such as the CI854 PROFIBUS DP interface, CI860 FF HSE interface, etc.), and some local S800 I/O clusters.

• In Redundant Configuration: By pairing with SS823 or SS832 diode voting units, two or more SD832 units can form a redundant power supply system, significantly enhancing the overall control system's availability and safety to meet the demands of critical process applications.

• Compatibility: The SD832 is designed for easy installation on standard industrial DIN rails, seamlessly integrating with the mechanical structure of the AC 800M system. Its output complies with SELV (Safety Extra-Low Voltage) and PELV (Protected Extra-Low Voltage) standards, ensuring safety for personnel and equipment.

Core Features and Benefits

1. High-Reliability Design: Utilizes switched-mode power supply technology with a wide input voltage range, adapting to fluctuating industrial grids. It integrates internal input surge suppression, overvoltage, overcurrent, and short-circuit protection, ensuring stable operation in harsh electrical environments and providing "clean" power to downstream sensitive control equipment.

2. Easy Integration and Maintenance: Features standard snap-on DIN rail mounting, allowing for quick and tool-less installation or removal, greatly simplifying panel assembly and subsequent replacement procedures. The compact width (only 32mm) optimizes space utilization within control cabinets.

3. Supports Redundant Configuration: The SD832 can easily form an N+1 redundant power supply system with other power modules in the series (e.g., SD834) by connecting to an external SS823 or SS832 diode voting unit. If any power supply fails, the voting unit automatically isolates it, allowing the remaining healthy units to seamlessly continue powering the load, achieving high system availability. This is particularly crucial for demanding applications like AC 800M High Integrity (HI).

4. Excellent Safety Compliance: Fully complies with EU CE directives (including EMC and LVD), North American UL standards, and other international electrical safety norms. The output circuit meets SELV/PELV requirements, providing an intrinsically safe secondary-side voltage that effectively protects operators and field equipment.

5. High Efficiency and Thermal Management: Conversion efficiency exceeding 89% reduces energy waste, lowering operational costs and temperature rise inside the cabinet. Clear mounting clearance requirements (15mm lateral, 40mm vertical) guide users toward optimal thermal layout.

6. Soft-Start and Low Interference: The built-in soft-start circuit effectively suppresses inrush current at power-on, preventing nuisance tripping of upstream circuit breakers or fuses. Superior output filtering results in very low ripple, avoiding interference with precision analog I/O modules.

Installation and Configuration Guidelines

Safety Precautions Before Installation

• De-energize Before Working: Ensure the main power supply is completely disconnected before mounting the SD832 to the DIN rail or performing any wiring.

• Electrostatic Discharge (ESD) Protection: As electronic equipment, handle with ESD precautions; wearing a grounded wrist strap is recommended.

• Environmental Check: Ensure the installation environment is free from condensation, conductive dust, strong corrosive gases, and that the ambient temperature is within the specified range.

• Read the Manual: Before installation, thoroughly read the "Safety Summary" and "Installation" sections of the AC 800M Controller Hardware user manual.

Mechanical Installation Steps

1. Mount the Rail: Securely mount the standard TS 35/7.5 DIN rail onto the control cabinet backplane or mounting plate.

2. Reserve Space: Reserve at least 15mm of space on both the left and right sides of the planned SD832 location, and at least 40mm of space above and below, to ensure airflow and heat dissipation.

3. Mount the Module: Align the top hook on the back of the SD832 module with the upper edge of the DIN rail. Press down and rotate the module so that the bottom snap-fit latch engages the lower edge of the rail. A audible "click" indicates proper installation.

4. Verify Locking: Ensure the module is firmly seated and does not wobble.

Electrical Wiring Steps

1. Input Power Connection:

• Use appropriate wiring (recommended 1.0-2.5 mm²) to connect the AC or DC input power to the module's input terminals (L, N, PE).

• PE (Protective Earth) must be reliably connected to the cabinet grounding busbar. This is critical for meeting Class I equipment safety and EMC performance.

• In the input circuit, install a branch protection and isolation device, such as a miniature circuit breaker (MCB) or time-delay fuse rated 10-20A as recommended in the specifications table.

2. Output Power Connection:

• Connect the output DC 24V (+24V) and 0V (M) to the power distribution terminal block of the AC 800M system or directly to the power input terminals of the CPU baseplate (e.g., TP830).

• Observe output polarity to avoid reverse connection.

• In redundant configurations, the outputs must be connected via an SS823/SS832 voting unit. Never directly parallel the outputs of multiple power supplies.

3. Wiring Check: Confirm all screw terminals are tightened, cables have no exposed strands, and wiring is neat. Avoid running power cables tightly parallel to communication cables (e.g., CEX-Bus, ModuleBus, Ethernet); maintain a minimum distance of 10cm to reduce interference.

Configuration Considerations

• Voltage Range Selection: The SD832 features automatic input range selection; no manual jumper setting is required. However, before initial power-up, verify that the site supply voltage is within the 90-132V or 180-264V range.

• Redundant System Configuration: In systems like AC 800M High Integrity, redundant power supply configuration (using SS823) is strictly defined and must follow the standard diagrams provided in the manual. It is not allowed to arbitrarily modify the configuration via individual circuit breakers between modules.

Operation, Maintenance, and Troubleshooting

Power-up and Operational Status Indication

• After power-up, the green "Output OK" LED indicator on the SD832 front panel should illuminate steadily, indicating normal 24V output.

• Verify the output voltage by measurement, confirming it is within the 24V ±1% range.

Preventive Maintenance

• Regular Inspection: It is recommended to periodically check, aligned with system maintenance cycles, that the power module has adequate ventilation and to clear any accumulated dust. Inspect terminal connections for signs of loosening or oxidation.

• Spare Parts and Replacement: To minimize system downtime, it is advisable to maintain a stock of spare units of the same model. When replacing, always follow the "Online Replacement" procedure (if supported by the system) or plan for a scheduled downtime replacement.

Troubleshooting Reference

If the SD832 malfunctions (e.g., LED off, no output, or abnormal output voltage), refer to the following steps:

1. Check Input Power: Measure the voltage between input terminals L-N or L-PE to ensure it is normal.

2. Check Fuse/Circuit Breaker: Check if the upstream protective device has tripped.

3. Check Load: Disconnect the output load and measure the no-load output voltage to determine if the issue is a power supply fault or protection triggered by a short circuit/overload on the load side.

4. Check Ambient Temperature: Confirm if the module has entered thermal protection due to excessively high ambient temperature.

5. Replacement Test: If possible, test by replacing with a known-good unit of the same model.

Important Warning: Do not attempt to disassemble or repair the power module unless you are a qualified professional. Faulty modules should be returned to a professional service facility or disposed of properly.

Application Scenarios

The SD832 is suitable for a wide range of industrial control fields, particularly:

• Process Automation: Distributed Control Systems (DCS) in chemical, oil & gas, pharmaceutical, water treatment, and other industries.

• Factory Automation: Programmable Logic Controller (PLC) systems in automotive manufacturing, food & beverage, packaging, material handling, and other sectors.

• High Integrity Systems: Forms part of the AC 800M HI controller with PM865, SM810/SM811, etc., for Safety Instrumented Systems (SIS) requiring Safety Integrity Level (SIL) 2 or 3.

• Infrastructure: Building automation, energy management, substation automation.

Comparison with Other SD83x Power Supplies

To aid in model selection, the table below provides a brief comparison of key models within the SD83x series:

Table 2: SD83x Series Power Module Selection Comparison