ABB 3BHB018104R0001 — High-Integrity Redundant Power Supply Module for AC 800M DCS Systems

Let’s cut to the chase: this isn’t just another power supply. The ABB 3BHB018104R0001 is a dual-redundant, hot-swappable 24 VDC power module designed specifically for mission-critical segments of ABB’s AC 800M distributed control systems—think turbine control rooms, refinery safety shutdown loops, or continuous pharmaceutical batch lines where even a 200-millisecond brownout could trigger a cascade trip.

One thing I appreciate is how seamlessly it integrates into existing AC 800M cabinets—no extra backplane adapters, no firmware re-flashing required. It plugs directly into the S800 I/O rack or the PM866/PM891 controller base, and the status LEDs (green “OK”, amber “Warning”, red “Fault”) give you unambiguous diagnostics without pulling up Control Builder M.

Key Features

• True 2-out-of-2 redundancy: Both modules share load continuously; if one fails, the other picks up 100% of the load—no interruption, no reset. From my experience, this avoids ~70% of unplanned outages tied to single-point PSU failures in legacy installations.
• Wide-input AC/DC compatibility: Accepts 85–264 VAC or 100–300 VDC—handy when retrofitting older plants with mixed UPS feeds or DC battery banks.
• Integrated isolation & surge protection: Built-in 4 kV transient immunity (per IEC 61000-4-5) and reinforced galvanic isolation between input and output—critical near VFDs or high-energy switchgear.
• Hot-swap capable with soft-start: You can replace it under full load; the inrush limiter prevents voltage sag on adjacent modules. A customer in Rotterdam told us they swapped one mid-shift during a steam turbine commissioning—zero process disturbance.
• Diagnostic interface via S800 bus: Delivers real-time voltage, current, temperature, and lifetime wear estimates straight into ABB’s System 800xA—no need for external meters or manual logging.

Technical Specifications

Application Fields

This module shows up where uptime isn’t just preferred—it’s non-negotiable. Think offshore platform fire & gas systems, nuclear auxiliary feedwater controllers, or continuous polymer extrusion lines running 24/7. In many cases, engineers specify it not because their old PSUs failed, but because their insurance provider mandated SIL 2-compliant power architecture—and this unit carries ABB’s internal SIL 2 assessment (IEC 61508 Part 2, claimed PFH < 1.9 × 10⁻⁷/h).

You might notice it’s rarely used in standalone PLC cabinets—it’s purpose-built for AC 800M ecosystems. If your site runs System 800xA or has legacy PM86x controllers, this fits like a glove. Drop it into a non-ABB system? Not advisable—the S800 bus handshake won’t negotiate.

Advantages & Value

Procurement teams typically weigh three things: lifecycle cost, integration risk, and support velocity. Here’s how this module stacks up:

• No hidden integration labor: Saves ~16 engineering hours vs. third-party redundant PSUs that require custom logic blocks or separate monitoring gateways.
• Lower TCO over 10 years: Rated MTBF > 500,000 hours; field data suggests median service life exceeds 12 years before capacitor degradation triggers replacement—longer than most AC 800M controllers it powers.
• Supply chain confidence: ABB maintains active production (not EOL or last-time-buy), and we carry buffer stock—so delivery stays at 1 week if ordered in-stock. No surprises.

Installation & Maintenance

Mount it in an IP20-rated cabinet with ≥ 100 mm clearance above/below for convection cooling. Avoid installing beside heat-generating components like thyristor drives—ambient must stay under 60 °C at the module’s air inlet. Wiring: use 2.5 mm² stranded copper (min. 75 °C rating) for input; torque terminal screws to 0.5 N·m (don’t overtighten—those brass inserts strip easily).

Safety first: always de-energize the main AC feed before inserting/removing—even though it’s hot-swap capable, arc-flash risk remains if shorted tools bridge terminals. Routine maintenance? Just two things: visually inspect vent slots every 6 months (dust buildup = derating), and run a diagnostic read via 800xA annually. Firmware updates are rare—ABB hasn’t issued one since 2021, and it appears stable across all current 800xA versions (6.1 through 6.4.1).

Quality & Certifications

It’s CE-marked (EMC Directive 2014/30/EU, LVD 2014/35/EU), UL 61010-1 listed (File E236022), RoHS 2011/65/EU compliant, and carries ABB’s 365-day warranty—start-to-finish, no pro-rata clauses. The unit ships with traceable calibration records (NIST-traceable voltage/current verification at 25 °C), and ABB’s global service network supports field-level firmware recovery or RMA within 5 business days.