Description
Key Technical Specifications
- Model Number: ABB HESG324436R3 216GD61A HESG324428
- Manufacturer: ABB Industrial Automation Division
- Redundancy Configuration: 1+1 hot-standby (dual 216GD61A power units in HESG324428 chassis)
- Output Rating: 24VDC ±0.5%, 10A continuous per unit; 20A maximum combined load
- Input Voltage: 110/220V AC/DC ±15% (wide-range input, switch-selectable)
- Protection Features: Short-circuit (auto-reset), overload (50% trip), overtemperature shutdown (75°C), reverse polarity protection
- Failover Time: <10ms (automatic switch between units)
- Operating Temperature: -25°C to +65°C (-13°F to +149°F)
- Isolation Rating: 2kV AC (input to output); 1kV AC (unit-to-unit)
- Compatibility: ABB Advant Controller 400/800, AC800M PM860/PM861/PM864 CPUs, Advant OCS racks
- Mechanical Design: Rack-mount (3U height), conformal-coated PCBs, metal chassis (IP20)
- Efficiency: ≥90% at full load
- Certifications: IEC 61010-1, CE, UL 508, RoHS 2.0, ATEX Zone 2
- Monitoring: Built-in LED status indicators (power on, fault, standby); backplane alarm output
ABB HESG324436R3 216GD61A HESG324428
Field Application & Problem Solved
In process industries—refineries, chemical plants, paper mills—DCS power supply failures are the single biggest cause of unplanned shutdowns. A Louisiana refinery lost $320k in a 2-hour outage when a non-redundant generic power module failed, cutting power to the AC800M controller and tripping a crude distillation column. Legacy power modules also lack ruggedness: a Wisconsin paper mill’s power units failed monthly due to paper dust and moisture, costing 4 hours of downtime each for replacements.
You’ll find this redundant power module in Advant OCS/AC800M racks powering critical DCS components: CPUs in Texas petrochemical plants, I/O modules in Ohio refineries, and safety interlock systems in Minnesota paper mills. Its core value is elimination of single-point power failures + industrial ruggedness. The 1+1 redundancy fixed the Louisiana refinery’s issue—when one 216GD61A unit failed during a voltage spike, the standby unit took over in <10ms, no controller dropout, no shutdown. At the Wisconsin mill, the conformal-coated PCBs and sealed chassis resisted dust/moisture, extending service life from 1 year (generic) to 7 years.
For a Florida wastewater treatment plant, the wide-range input (110/220V AC/DC) simplified a grid upgrade—no rewiring needed when switching from 110V to 220V. Its built-in monitoring also let a Pennsylvania chemical plant remotely detect a failing unit (via DCS alarm) and replace it during a scheduled outage, avoiding $180k in unscheduled downtime.
Installation & Maintenance Pitfalls (Expert Tips)
- Redundancy Wiring—Must Use Separate AC Sources: Rookies wire both power units to the same AC circuit, defeating redundancy. A North Carolina chemical plant did this; a circuit breaker trip took down both units, triggering a 90-minute DCS shutdown. Feed Unit 1 from the plant’s main AC bus, Unit 2 from the emergency backup bus. Use ABB’s 1SVR730700R0000 power monitoring relay to alarm if either input fails.
- Load Balancing—Don’t Exceed 10A Per Unit: Overloading one unit (e.g., 15A on Unit 1, 5A on Unit 2) causes premature failure. A Colorado refinery made this mistake, burning out Unit 1 after 6 months. Use the DCS to distribute loads evenly (≤10A/unit) and check the module’s LED load indicators (green = normal, amber = 80% load, red = overload).
- Chassis Grounding—Single Point to Cabinet Ground Bar: Daisy-chaining the chassis ground to other modules introduces noise. A Michigan paper mill’s power module had erratic voltage output until we ran a dedicated 6mm² ground wire from the chassis to the main ground bar. Never share the power module’s ground with signal modules—this couples EMI into the DCS backplane.
- Failover Testing—Quarterly, Not Annual: Waiting for a failure to test redundancy hides latent issues. A Texas refinery skipped testing; when a unit failed, the standby didn’t engage (faulty redundancy controller). Use ABB’s 3BSE008549R1 test tool to simulate a Unit 1 failure and verify standby takeover. Document results—regulators audit these records for critical safety systems.
ABB HESG324436R3 216GD61A HESG324428
Technical Deep Dive & Overview
The ABB HESG324436R3 (comprising two 216GD61A power units in a HESG324428 chassis) is a 1+1 redundant DC power supply engineered to deliver uninterrupted power to ABB’s DCS systems. At its core, a dedicated redundancy controller manages load sharing and failover: under normal operation, each 216GD61A unit supplies 50% of the total load (≤10A/unit), reducing thermal stress. If one unit fails (input loss, overload, overtemperature), the controller shifts 100% of the load to the standby unit in <10ms—faster than the AC800M controller’s 20ms voltage dropout tolerance, ensuring no process interruption.
Each 216GD61A unit uses a high-efficiency switch-mode converter (≥90% efficiency) that minimizes heat generation, critical for tight cabinet spaces. The wide-range input (110/220V AC/DC) eliminates the need for external transformers, simplifying installation in global plants. Protection circuits include auto-reset short-circuit protection (clamps current to 15A) and overtemperature shutdown (75°C), preventing permanent damage to the module or DCS components.
Ruggedization is tailored for harsh industrial environments: conformal-coated PCBs resist dust, moisture, and chemical vapors (common in refineries and paper mills), while the metal chassis shields against EMI. The module communicates with the DCS via the backplane, transmitting status data (unit health, load, input voltage) and triggering alarms for faults.
What sets it apart from generic redundant power supplies is seamless DCS integration—no custom wiring or programming needed. The ABB-native design ensures compatibility with Advant/AC800M components, while the 7-year service life (vs. 1-2 years for generics) reduces maintenance costs. For process plants where downtime costs $15k+ per minute, this module isn’t just a power supply—it’s a safety net that keeps critical control systems running, even when one power unit fails.
