Application Scenarios

In a pharmaceutical batch reactor control system, the automation cabinet houses a redundant pair of safety controllers, their associated I/O, and network cards. A power supply failure in this cabinet could halt a multi-day batch process, resulting in the loss of millions of dollars in product and cleanup costs. The ABB Saft 190 APC Power Supply Card​ is deployed in an N+1 redundant configuration within this cabinet. Two or three modules share the total load of the rack. Each module independently converts incoming AC power to the precise DC voltages required by the system backplane. Their integrated load-sharing circuitry ensures even distribution. More critically, the hot-swappable design allows a plant technician to remove and replace a Saft190APC​ module that shows a pre-fail warning or has failed, without ever powering down the control system. This capability directly addresses the paramount need for uninterrupted control system operation, transforming power from a single point of failure into a resilient, maintainable subsystem that protects the integrity of high-value production batches.

 

 

Parameter

Main Parameters	Value/Description
Product Model​	ABB Saft 190 APC / Saft190APC​
Manufacturer​	ABB (Asea Brown Boveri)
Product Category​	Hot-Swappable Redundant Power Supply Card / Module
Input Voltage​	Wide range AC input, typically 100-240V AC, 50/60 Hz. Allows for global deployment.
Output Voltage(s)​	Provides regulated DC output(s) for system backplane, e.g., +5V, +24V, and +/-15V​ as required by controller and I/O electronics.
Output Power​	Designed to deliver sufficient power (e.g., 150W, 250W) for a fully populated system slot or rack segment.
Redundancy Support​	N+1 Redundancy.​ Multiple modules operate in parallel with active current sharing. Failure of one does not affect system operation.
Hot-Swappable​	Yes.​ Can be inserted or removed from a live system rack without tools and without interrupting power to the load.
Efficiency​	High efficiency (>85%) to minimize heat generation and energy loss within the cabinet.
Protection Features​	Integrated protection against: Overload, Overvoltage, Short-Circuit, and Overtemperature.
Cooling​	Internal temperature-controlled fan for forced-air cooling. Ensures stable operation in enclosed panels.
Status Indication​	Comprehensive LED indicators for AC OK, DC OK, Load Share, and Fault​ status.
Mounting​	Slides into a dedicated power supply slot on a Saftronics or compatible ABB system rack.
Communication/Monitoring​	May provide analog or contact signals for remote monitoring of status and alarms (e.g., DC Fail, Fan Fail).
Primary Application​	Providing resilient power to controller racks in Saftronics drives, high-availability AC 800M systems, or critical process control units.

 

 

 

Technical Principles and Innovative Values

• Innovation Point 1: True Live Insertion and Removal (Hot-Swap)The ABB Saft190APC​ incorporates advanced hot-swap controllers and staggered pin connectors. This ensures that when a module is inserted or removed, the power sequencing is controlled: ground connects first, followed by sense lines, and finally the main power lines. This prevents arcing, back-feeding, and voltage transients on the shared backplane. This allows for the maintenance or replacement of a power module while the control system remains fully operational, a critical feature for systems with 99.99%+ availability targets.
• Innovation Point 2: Advanced Active Current Sharing for True N+1 RedundancyThe modules employ a precise active current-sharing bus. This technology ensures that all parallel Saft 190 APC​ modules contribute equally to the total load. It actively balances the output current between modules, preventing any single unit from being overstressed, which maximizes the life of all units. In the event of a module failure, the remaining units instantly and seamlessly pick up the full load without any interruption or voltage dip, providing inherent and transparent redundancy.