Product Core Brief

• Model: SD822
• Order Code: 3BSC610038R1 (verify on nameplate)
• Brand: ABB
• Series: ABB S800 I/O system power supply device
• Core Function: Converts 100-240 V AC input to 24 V DC at 5 A; supplies power to S800 I/O modules and can optionally supply 24 V to field instruments.
• Product Type: 24 V DC power supply device
• Key Specs: 5 A output | 100-240 V AC input | 300 V isolation | Redundant configuration compatible | SS822 redundancy unit compatible
• Condition: New Original / New Surplus (verify by full order code)

Key Technical Specifications

• Part Number:
• Order Code: 3BSC610038R1 (listed in ABB spare parts references; confirm against the actual nameplate)
• Input Voltage: 100-240 V AC, selectable 115/230 V AC
• Output Voltage: 24 V DC
• Output Current: 5 A (rated)
• Isolation Voltage: 300 V
• Protection: Short-circuit protection on output; overload/overvoltage protection per product design
• Redundancy: Two SD821/SD822/SD823 units can be paralleled for redundant 24 V DC supply; commonly paired with SS822 power voting unit
• Dimensions: Approximately 110 × 125 × 65 mm (D × H × W); verify against nameplate
• Weight: Approximately 0.7 kg
• Mounting: DIN-rail / C-rail mounted power supply device for S800 I/O station assembly
• Environmental Compliance: Standard versions are listed as G2 compliant; G3-compliant versions may also exist for more corrosive environments
• Lifecycle Status: Legacy component; verify current ABB lifecycle phase before long-term deployment

Product Introduction (No Fluff)

The ABB SD822 is a 24 V DC / 5 A power supply device used in the S800 I/O system. It converts 100-240 V AC mains input into a regulated 24 V DC output to power communication modules, I/O modules, and optionally field instruments within an S800 I/O station.

Its practical value is maintaining legacy S800 I/O stations where the original power supply has degraded or failed. SD822 sits between SD821 (2.5 A) and SD823 (10 A) in the S800 power supply family, making it the mid-range option when a station has more I/O modules or field-side 24 V load than SD821 can support. For maintenance replacements, the full order code 3BSC610038R1 should be matched, since input voltage selection, output current rating, and redundancy behavior differ across SD821/SD822/SD823.

QA & Testing SOP (Dynamic & Transparent)

For legacy S800 power supply devices, we verify mechanical integrity and electrical readiness before shipping.

1. Order code verification — Confirm SD822 and 3BSC610038R1 on the label; check revision and country of origin markings.
2. Visual inspection — Inspect housing, DIN-rail clip, AC input terminals, 24 V DC terminals, and ventilation areas for corrosion, burn marks, or mechanical damage.
3. Input voltage selector check — Verify the 115/230 V AC selector switch position matches the site supply before energizing.
4. Insulation and short-circuit check — Confirm no short circuits between AC input, 24 V output, and protective earth.
5. Power-up verification — Where test fixtures are available, apply rated AC input and verify 24 V DC output, OK LED status, and load stability; pack with terminal and connector protection.

Installation Pitfalls & Guide (Engineer to Engineer)

❗ Match 3BSC610038R1 exactly. Do not substitute SD821 (2.5 A) or SD823 (10 A) without recalculating the station power budget and verifying mechanical/terminal compatibility.

❗ Verify the AC input selector. SD822 supports 115/230 V AC selection; applying 230 V AC with the selector set to 115 V can damage the unit.

❗ Calculate the 24 V load. Include all I/O modules, communication modules, fieldbus power, and any field-side 24 V instruments. A 5 A supply may be insufficient for heavily loaded stations.

❗ Handle redundancy wiring carefully. If two SD822 units are used in redundant configuration, confirm the wiring scheme and whether an SS822 voting unit is present. Incorrect parallel wiring can cause backfeed or uneven load sharing.

❗ Confirm G2 vs G3 compliance. Standard SD822 units are G2 compliant; if the cabinet is exposed to corrosive gases, verify whether a G3-compliant version is required.

Replacement steps:

1. Document the existing AC input voltage, selector position, 24 V wiring, and redundancy configuration.
2. Remove AC power and verify zero voltage before disconnecting input and output terminals.
3. Install the replacement SD822 with the same 3BSC610038R1 order code and correct AC voltage selector setting.
4. Restore power, verify 24 V DC output and OK LED, and confirm all I/O modules return to normal status.

Technical FAQ

What is the ABB SD822?
It is a 24 V DC / 5 A power supply device for the ABB S800 I/O system, converting 100-240 V AC to 24 V DC for I/O and communication modules.

What is the order code?
SD822 is commonly listed as 3BSC610038R1 in ABB spare parts references, but the nameplate should always be confirmed before ordering.

Can I replace SD821 with SD822?
Possibly, but only after confirming the 24 V load, mechanical fit, terminal layout, and system documentation. SD822 provides 5 A versus 2.5 A for SD821, so it is not a drop-in equivalence in every station.

Can it be used in redundant configuration?
Yes. Two SD821/SD822/SD823 units can be configured for redundant 24 V DC supply, often with an SS822 power voting unit.

Is it still available?
It is considered a legacy component. New surplus and verified replacements can be sourced, but long-term projects should evaluate migration to a supported ABB power supply platform.