Description

The ABB UNS0868B-P V2 (3BHE013940R0002)​ is a high-availability, hot-swappable power supply module engineered for ABB’s premium AC 800M controller family. It delivers clean, stable, and redundant DC power, forming the critical power foundation for mission-critical distributed control system (DCS) and safety controller racks.

Application Scenarios

In a large-scale liquefied natural gas (LNG) export terminal, the control system managing the complex cryogenic processes must operate with zero unscheduled downtime. A power supply failure in a controller rack could trigger a cascade shutdown, resulting in massive production and financial loss. Here, the ABB UNS0868B-P V2​ modules are deployed in a redundant (N+1) configuration within each critical AC 800M controller cabinet. If one power supply were to fail, the redundant partner instantly and seamlessly takes over the full load without a single blip in the controller’s operation. Maintenance engineers can then safely extract and replace the faulty UNS0868B-P V2​ module during normal operation. This scenario underscores its pivotal role in solving the paramount challenge of achieving maximum system availability and mitigating the risk of single-point failures in the power path of critical industrial automation.

Parameter

Technical Principles and Innovative Values

The ABB UNS0868B-P V2​ transcends the concept of a simple power converter; it is an intelligent, system-oriented power component designed for ultimate reliability in a control system.

Innovation Point 1: Advanced Current Sharing & True Hot-Swap Architecture.​ In a redundant setup, multiple UNS0868B-P V2​ modules employ an active current-sharing algorithm. This ensures they evenly distribute the electrical load, preventing any single unit from being overstressed, which maximizes overall lifespan. The true hot-swap design includes controlled inrush current limiting and electronic bus isolation, allowing for safe insertion and removal under full load without causing voltage dips or disturbances to the sensitive controllers.

Innovation Point 2: Intelligent PMBus-Based Health Management.​ The module integrates PMBus (Power Management Bus) communication. This allows the controller or a dedicated management tool to read real-time parameters such as output voltage/current, internal temperature, fan speed, and accumulated operating hours. It enables predictive maintenance by trending performance data and providing early warnings of potential issues, shifting from reactive to proactive power system management.

Innovation Point 3: Robust, Fan-Cooled Design for Harsh Environments.​ Engineered for 24/7 operation in industrial panels, it features a high-quality, long-life ball-bearing fan with speed adjustment based on thermal load. This design ensures adequate cooling in high ambient temperatures while optimizing fan life and minimizing acoustic noise. Its wide-range AC input (100-240V) allows for global deployment without hardware changes, simplifying spare parts inventory.

Application Cases and Industry Value

Case Study: Power System Upgrade in a Coastal Petrochemical Complex

A major petrochemical plant located in a region with unstable grid power experienced occasional brownouts that caused brief voltage sags. While the process controllers (AC 800M) had battery-backed UPS protection, the older, non-redundant power supplies in the racks were a vulnerability. A single sag-induced failure could take an entire controller node offline.

Solution & Outcome:​ The plant initiated a phased upgrade of power supplies in their most critical control cabinets. They standardized on the ABB UNS0868B-P V2. installing them in a redundant 1+1 configuration. Shortly after completion, a severe voltage sag occurred. One UNS0868B-P V2​ in a rack faulted due to the transient, but as designed, its partner immediately supported the entire load without interruption. The controller operation was unaffected. Plant engineers replaced the faulted module during normal production. The Engineering Manager reported: “The investment in the redundant UNS0868B-P V2​ power system paid for itself in that one event. The cost of an unplanned shutdown would have been astronomical. The PMBus data also helps us plan our maintenance rounds more effectively.”

Related Product Combination Solutions

The ABB UNS0868B-P V2​ is the core of a reliable power system for high-end ABB controllers and their peripherals.

AC 800M Controller Modules (PM/PP series):​ The primary loads protected by the UNS0868B-P V2. These high-performance controllers depend on its clean, stable power.

S800 I/O Communication Interfaces (CI modules):​ I/O racks connected to the AC 800M also require reliable power, often supplied from the same or a similarly designed system.

Power Supply Rack/Chassis:​ The physical enclosure designed to house multiple UNS0868B-P V2​ modules, providing the backplane and connectors for N+1 configurations.

Uninterruptible Power Supply (UPS):​ A system-level UPS (like an ABB PS series) typically provides conditioned AC power to the UNS0868B-P V2​ modules, creating a complete power protection chain from grid to logic.

System 800xA/Control Builder:​ The engineering software that can potentially read the PMBus data from the UNS0868B-P V2​ modules for system-wide health monitoring and asset management.

Redundant Communication Modules (e.g., CI854):​ These modules, which rely on the power from the UNS0868B-P V2. further enhance overall controller availability.

Installation, Maintenance, and Full-Cycle Support

Installation of the ABB UNS0868B-P V2​ is designed for safety and simplicity. The module slides into its designated bay in the power supply rack or controller base unit and connects via a sturdy blind-mate connector, ensuring correct alignment. The AC power input is connected to a terminal block at the rear. Key installation steps include verifying the input voltage matches the plant supply and ensuring proper grounding. In a redundant system, modules automatically synchronize and begin current sharing upon power-up.

Maintenance is revolutionized by its hot-swap capability. A module can be replaced in under a minute without tools during normal operation. Routine maintenance involves visual inspection of status LEDs (green for OK, red for fault) and ensuring the air intake vents are clean. The integrated smart features allow for condition-based monitoring; trends of rising temperature or decreasing efficiency can signal the need for proactive replacement. We provide comprehensive support for this critical component, from initial system design and redundancy planning to supplying guaranteed genuine modules. Our technical team can assist with configuration, diagnostics, and best practices for building a fault-tolerant power architecture with the UNS0868B-P V2​ at its core.

Contact us for expert consultation on designing a fault-tolerant power solution for your ABB control system or to source genuine, reliable UNS0868B-P V2 power supply modules.