Description
Key Technical Specifications
- Model Number: XXD129A01 (PEC800-BP)
- Manufacturer: ABB Process Automation Division (Control Systems)
- Product Type: Redundant Power Supply Module for AC 800PEC Control Systems
- System Compatibility: ABB AC 800PEC Controllers, ABB Symphony Harmony DCS, High Power Rectifier Control Systems
- Input Specifications:
- Voltage Range: 100-240VAC (50/60Hz)
- Power Factor Correction: >0.95 (at full load)
- Input Current: 8A (max) at 100VAC, 4A (max) at 240VAC
- Isolation Rating: 2500VAC (input to output)
- Output Specifications:
- Output Voltage: 24VDC ±1%
- Output Power: 800W (continuous)
- Output Current: 33.3A (max) at 24VDC
- Redundancy: 2+0 or 1+1 redundant configuration support
- Hot-Swappable: Yes, with zero downtime replacement
- Protection Features:
- Overvoltage Protection: 28VDC (latching)
- Overcurrent Protection: 35A (current limiting)
- Short Circuit Protection: Hiccup mode, automatic recovery
- Over Temperature Protection: 85°C (thermal shutdown)
- Mechanical Specifications:
- Dimensions (W×H×D): 100mm × 220mm × 300mm
- Weight: 2.8kg
- Mounting Type: 19″ rack mount (3U height), DIN rail compatible
- Environmental Specifications:
- Operating Temperature: 0°C to +50°C (ambient, derate >40°C)
- Storage Temperature: -40°C to +70°C
- Humidity: 5% to 95% (non-condensing)
- Vibration Resistance: Up to 2g (10-500Hz, IEC 60068-2-6)
- Certifications: CE, UL, IEC 61010-1, IEC 60950-1, RoHS Compliant
ABB XXD129A01
Field Application & Problem Solved
In power generation, aluminum smelting, and petrochemical industries, uninterrupted power supply to control systems is critical—even a 1-second power loss can cause catastrophic equipment damage or production downtime. At a Canadian aluminum smelter, a failed legacy power supply caused a 4-hour shutdown of a high-power rectifier ($870k in lost production). At a Texas power plant, a non-redundant power module failure halted a steam turbine generator set for 3 hours ($420k in lost generation).
The XXD129A01 (PEC800-BP) solves these critical issues by delivering:
- Redundant Power Architecture: Supports 1+1 redundant configuration, ensuring continuous operation even if one module fails
- High Power Density: 800W output in a compact 3U form factor, ideal for space-constrained control cabinets
- Hot-Swappable Design: Allows replacement without shutting down the control system, reducing maintenance downtime to minutes
- Wide Input Voltage Range: 100-240VAC input handles voltage fluctuations common in industrial environments
- Comprehensive Protection: Overvoltage, overcurrent, short circuit, and over temperature protection prevent damage to connected control components
Typical deployments:
- High Power Rectifiers: Aluminum smelting, electroplating, and chemical processing plants
- Turbine Control Systems: Steam/gas turbine generator sets in power plants
- Industrial Automation: ABB AC 800PEC-based control systems for pumps, compressors, and conveyors
- Critical Infrastructure: Refineries, petrochemical plants, and LNG facilities requiring 24/7 operation
Installation & Maintenance Pitfalls (Expert Tips)
- Redundant Configuration Requires Proper Cabling: At a Louisiana refinery, a technician connected both power modules to the same input circuit, negating redundancy. Always connect each PEC800-BP module to separate 100-240VAC input circuits with independent circuit breakers (10A minimum).
- Hot-Swap Procedure Must Be Followed: A technician at an Illinois power plant removed a module without waiting for the “OK to Remove” LED indicator, causing a momentary voltage dip. Wait for the green LED to illuminate solid before removing a module, and ensure the replacement module has the same firmware version (v3.2+ recommended).
- Ventilation is Critical for Heat Dissipation: Poor ventilation at a Michigan aluminum smelter caused modules to overheat and shut down. Maintain a minimum of 5cm clearance around all sides of the module and ensure cabinet airflow of 200CFM.
- Grounding Ensures Safety & Performance: Improper grounding at a Texas chemical plant caused EMI interference and false alarms. Ground the module to the cabinet chassis using a dedicated 16AWG ground wire and ensure the input power is properly grounded.
- Firmware Update Prevents Compatibility Issues: At a Pennsylvania power plant, mixing XXD129A01 firmware v2.1 with AC 800PEC controller v5.0 caused communication errors. Always update the module firmware to v3.0+ using ABB ServicePort software.
- Input Fuse Selection is Important: Using a 20A fuse instead of the recommended 10A at a Florida refinery caused a module to fail during a power surge. Install ABB-recommended 10A slow-blow fuses (part number 1SFA061000R1000) on each input circuit.
ABB XXD129A01
Technical Deep Dive & Overview
The ABB XXD129A01 (PEC800-BP) is a high-reliability redundant power supply module designed specifically for ABB’s AC 800PEC control system. It delivers 800W of continuous power at 24VDC, providing the critical energy needed to keep industrial control systems operational in the world’s most demanding environments.
Internally, it uses a switch-mode power supply (SMPS) topology with active Power Factor Correction (PFC) >0.95, reducing harmonic distortion and improving energy efficiency. The module features two independent power conversion stages, enabling seamless transition between modules in a redundant configuration. It incorporates advanced digital control circuitry that monitors output voltage, current, and temperature in real-time, triggering protective shutdowns when thresholds are exceeded.
What makes it field-tough is its hot-swappable design—a game-changer for critical applications where downtime is measured in millions of dollars per hour. The module also includes LED status indicators (power, fault, OK to remove) that provide instant visual diagnostics, reducing troubleshooting time from hours to minutes.
For field teams, it’s the gold standard for powering AC 800PEC controllers. At a Midwestern power plant, retrofitting legacy power supplies with XXD129A01 modules reduced control system failures by 92% and extended maintenance intervals from 6 to 24 months. In a Canadian aluminum smelter, its redundant architecture prevented 17 potential shutdowns in a single year, saving $2.8M in production losses.
Unlike generic power supplies, the XXD129A01 is factory-tested to ABB’s strict industrial standards, ensuring compatibility with AC 800PEC controllers and other ABB control system components. It’s the unsung hero of industrial automation—delivering the reliability, durability, and performance needed to keep critical processes running when failure is not an option.
