ABB 560PSU02 1KGT011900R0001 Power Supply Unit Module

I. Overview

• Supporting a wide-range AC input (85-264V AC) to adapt to grid voltages in different regions;

• Providing a stable DC output voltage (optional 24V DC/48V DC, with an accuracy of ±1%) to meet the power supply requirements of different load equipment;

• Featuring a redundant parallel operation function (up to 6 modules in parallel), where other modules automatically share the load when a single module fails, ensuring no power supply interruption;

• Incorporating a built-in charging management circuit that can charge backup battery packs (such as lead-acid batteries and lithium batteries) to achieve seamless power-off switching (switching time ≤10ms);

• Equipped with overvoltage, overcurrent, and overtemperature protection functions to prevent damage to load equipment;

• Supporting power status monitoring (output voltage, load current, fault information) via the ABB Control Builder M software;

• Adopting a compact design to fit the limited installation space in industrial control cabinets.

• Input and Output Circuit: The AC input range is 85-264V AC (compatible with 50/60Hz), and it supports an optional DC input of 120-370V DC; the DC output is optional 24V DC/48V DC, with an output current of 20A (for the 24V version)/10A (for the 48V version) and an output accuracy of ±1%; it is equipped with input surge protection (10kV lightning protection), output overvoltage protection (upper limit of 28V for the 24V version), and overcurrent protection (triggered when the current reaches 150% of the rated current);

• Redundancy and Battery Management: It supports parallel redundancy of up to 6 modules, with a built-in current-sharing circuit (current-sharing error ≤5%), so the failure of a single module does not affect the overall power supply; it is equipped with a battery charging interface (compatible with 24V/48V), supports automatic switching between floating charge/equalizing charge modes, with an adjustable charging current of 0-5A, and the battery switching time is ≤10ms when the power is cut off;

• Heat Dissipation and Protection: It adopts an efficient heat dissipation design (aluminum heat sink + natural convection) with a fanless structure (to avoid dust blockage). The operating temperature range is -25℃~70℃, and the storage temperature range is -40℃~85℃; the shell is made of flame-retardant ABS material (UL94 V-0 grade) with an IP20 protection rating, suitable for the dust-proof environment of industrial control cabinets;

• Monitoring and Communication: It has built-in voltage, current, and temperature detection circuits, and supports local status display via LED indicators (power normal, fault, battery mode); it is equipped with an RS485 communication interface (Modbus protocol), which can be connected to the DCS system for remote monitoring and supports active reporting of fault alarms (such as overtemperature and overcurrent).

II. Technical Parameters

1. Input and Output Parameters

2. Redundancy and Battery Management Parameters

3. Environmental and Reliability Parameters

III. Functional Features

1. Wide-Voltage Input + High-Precision Output for Complex Grid Environments

• Ultra-Wide 85-264V AC Input: It adapts to power grids in different regions worldwide (such as 220V AC in China and 110V AC in the United States) and tolerates grid fluctuations (e.g., power plant voltage of 180-240V AC and factory voltage dropping to 150V AC during peak power consumption). When the input voltage changes by ±30%, the output accuracy remains stable at ±1%, avoiding the restart of control modules due to grid fluctuations;

• Low-Ripple and High-Stability Output: The output ripple is ≤50mVrms (for the 24V version), which is much lower than the industry average (100mVrms). It provides clean power for control modules such as the XVC768116, reducing signal acquisition noise (e.g., the temperature acquisition error is reduced from ±0.2℃ to ±0.1℃);

• AC/DC Input Compatibility: It optionally supports a 120-370V DC input, adapting to scenarios such as photovoltaic power supply and DC bus (e.g., power plants in remote areas). No additional rectification equipment is required, reducing system integration costs.

2. Multi-Module Redundant Parallel Operation for "Zero-Interruption" Power Supply

• 6-Module Parallel Fault Tolerance: Up to 6 modules can operate in parallel. With a built-in current-sharing circuit (current-sharing error ≤5%), when a single module fails, the remaining modules instantly share the load, and the output voltage fluctuation is ≤±0.5%. In a chemical DCS system with 3 parallel modules, there were no shutdowns during 2 module failures over 2 years of operation, avoiding production losses;

• Millisecond-Level Fault Switching: The module's fault detection response time is ≤100μs, and the redundant switching time is ≤0.5ms, which is much faster than the power-off tolerance time of control modules (usually ≥10ms), ensuring no data loss from the controller and no incorrect actions of actuators;

• Hot-Swappable Maintenance: It supports hot swapping to replace faulty modules, and the output voltage remains stable during the replacement process. A power plant replaced a faulty module online in 5 minutes without affecting boiler control (traditional power supplies require a 1-hour shutdown).

3. Intelligent Battery Management for Sudden Power Outages

• Seamless Power-Off Switching: When the mains power is cut off, the backup battery switches to supply power within 10ms, with no perception by the load. A sewage treatment plant experienced a 3-hour power outage, but the aeration tank control continued to operate, ensuring the sewage was discharged up to standard;

• Adaptive Charging Mode: It automatically switches between floating charge and equalizing charge modes based on the battery status (e.g., starting equalizing charge when the battery voltage is low and switching to floating charge after full charging), extending the battery life (the service life of lead-acid batteries is extended from 3 years to 5 years);

• Battery Status Monitoring: It real-time detects the battery voltage and charging current, and reports the data to the DCS system via the communication interface. It issues an early alarm when the battery capacity is insufficient. A steel plant detected battery aging 7 days in advance, avoiding the risk of sudden power outages.

4. Wide-Temperature Fanless Design for Harsh Industrial Environments

• Wide-Temperature Operation (-25℃~70℃): It uses low-temperature resistant capacitors (starting at -55℃) and high-temperature resistant components (resistors with a temperature resistance of 125℃). In the cold rolling workshop of a steel plant (-20℃) and near chemical reactors (60℃), the output accuracy does not degrade, and it operates continuously for 3 years without faults;

• Fanless Dust-Proof Design: It adopts aluminum heat sinks and natural convection for heat dissipation, avoiding fan wear and dust blockage. In the control cabinet of a cement plant (a high-dust environment), the module operated for 2 years without heat dissipation faults, and the temperature remained below 55℃;

• Strong Anti-Interference and Vibration Resistance: The electromagnetic shielding shell (shielding effectiveness ≥40dB) and anti-vibration structure (withstanding 1g acceleration) ensure that the output voltage ripple does not increase and the controller operates stably near the steam turbine of a power plant (with strong electromagnetic interference and vibration).