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The primary role of the ABB SS822 is to eliminate single points of failure in the power supply chain of an AC 800M rack. In critical processes, the loss of a PLC rack can result in costly shutdowns, safety incidents, or product loss. The ABB SS822 accepts inputs from two independent 24 VDC power supplies (typically ABB SD821, SD822, or SD823 units) and combines them into a single, reliable output.

Voting Logic: The ABB SS822 uses internal diodes to isolate the two inputs. It automatically selects the healthy source without interruption.

Fail-Safe Indication: If one input drops below a specific threshold, the ABB SS822 triggers a "Power Fail" alarm via a potential-free contact, alerting the control system before the backup battery (if present) is engaged or before the CPU shuts down.

No Firmware: As a purely hardware device, the ABB SS822 has no firmware, no IP address, and requires no software licensing, simplifying maintenance and replacement.

Technical specifications for the ABB SS822 ensure compatibility with standard industrial power systems:

Input Voltage: Dual input channels accepting 24 VDC (typical range 19–30 VDC) from redundant power supplies.

Output Current: Capable of handling the total load current of the AC 800M rack (typically up to 10A or more, depending on the specific rack configuration and thermal limits).

Voltage Drop: Minimal voltage drop across the internal diodes to ensure the CPU receives sufficient voltage.

Alarm Contact: Includes a changeover relay contact (potential-free) that signals input failure. This contact opens or closes when one of the inputs is lost, allowing integration into the plant's Distributed Control System (DCS) or alarm panel.

Mounting: Designed for DIN rail mounting within the AC 800M controller rack, sitting physically between the power supply units and the CPU/communication modules.

Part Number: Commonly associated with order codes like 3BSE018103R1 (verify specific order code for your region/project).

Correct installation of the ABBSS822is vital for the redundancy scheme to function correctly:

Positioning: Install the ABB SS822 on the DIN rail immediately after the power supply units and before the PM8xx CPU module. It acts as the bridge distributing power to the backplane bus.

Wiring Inputs: Connect two independent 24 VDC power sources to the two input terminals of the ABB SS822. These sources should ideally be fed from different UPS systems or power distribution panels to ensure true redundancy.

Wiring Outputs: The output of the ABB SS822 connects directly to the power distribution terminals of the AC 800M rack.

Alarm Wiring: Wire the potential-free alarm contact to a digital input on a monitoring system or an external alarm light. This allows operators to see a "Power Supply A Fault" or "Power Supply B Fault" indication immediately.

Torque Settings: Ensure all terminal screws on the ABB SS822 are tightened to the manufacturer's specified torque to prevent heating and voltage drops.

The ABB SS822 operates passively but provides clear status indications:

Normal Operation: When both input power sources are healthy, the green LED(s) on the ABB SS822 (if equipped, depending on revision) will be illuminated, and the alarm contact will be in its normal state.

Single Source Failure: If one power supply fails or its voltage drops, the ABB SS822 instantly isolates the failed source and draws full current from the remaining healthy source. The alarm contact changes state to signal the fault.

Load Sharing: While the ABB SS822 allows both supplies to share the load under normal conditions due to parallel operation, its primary design ensures seamless takeover rather than precise load balancing.

Restoration: When the failed power source is restored, the ABB SS822 automatically reintegrates it into the parallel configuration without interrupting the load. The alarm resets automatically once both inputs are stable.

Maintenance for the ABB SS822 is minimal due to its solid-state nature, but regular checks are recommended:

Visual Inspection: Periodically check the ABB SS822 for any signs of overheating, discoloration, or physical damage.

LED Status Check: Verify that the status LEDs indicate both channels are active during routine rounds.

Alarm Testing: Simulate a power loss on one input (by switching off one supply breaker) to verify that the ABB SS822 switches seamlessly and that the alarm contact correctly triggers the monitoring system. Note: Perform this test during a planned maintenance window.

Connection Tightening: Annually check and retighten the terminal connections on the ABB SS822 to prevent loosening due to thermal cycling.

Cleaning: Keep the module free of dust and conductive debris using compressed air.

Independent Sources: The redundancy provided by the ABB SS822 is only effective if the two input power supplies are fed from truly independent sources. Feeding both inputs from the same breaker defeats the purpose.

Voltage Compatibility: Ensure the input voltage matches the rated range of the ABB SS822. Overvoltage can damage the internal diodes.

Replacement: If replacing the ABB SS822, ensure the new unit is the exact model compatible with your AC 800M hardware version. No software download is needed, but physical fitment must be correct.

Hot Swapping: While the system is designed for redundancy, exercise caution when replacing the ABB SS822 itself. Although the second power supply should hold the load, it is best practice to follow specific hot-swap procedures defined in the AC 800M hardware manual to avoid transient glitches.

Environment: Install the ABB SS822 in a controlled environment within the specified temperature and humidity limits to ensure long-term reliability of the electronic components.

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