Introduction
A large automotive parts manufacturer experienced frequent production stoppages due to power supply failures in its control cabinets. Each failure caused hours of downtime and significant financial losses. The plant needed a reliable redundant power solution to ensure continuous operation of critical PLCs and safety systems. The ABB SS822 Power Voting Unit emerged as the ideal choice for this challenge.
Customer Challenge
The plant's existing single-power-supply architecture created a single point of failure. When a power supply failed, the entire production line shut down. Downtime events averaged four hours each, costing over $50,000 per incident in lost production and emergency maintenance. The maintenance team spent excessive time troubleshooting and replacing failed units. The plant required a solution that could seamlessly switch between two power sources without interrupting operations.
The Solution
The ABB SS822 Power Voting Unit directly addressed the plant's need for power redundancy. With dual 24V d.c 20A inputs and a single 24V d.c. 20A output, the SS822 allows two independent power supplies to feed a single load. Each power input is supervised, providing immediate fault detection. The unit works with power supplies SD821/822/823, which the plant already used. Installation was straightforward thanks to the DIN rail mounting and compact 50 mm width. The plant deployed SS822 units across ten critical control cabinets.
Results and Benefits
After implementing the SS822, the plant eliminated unplanned downtime caused by power supply failures. The supervised inputs alerted maintenance teams to failing power supplies before they caused a shutdown. The plant achieved a 99.9% uptime improvement in the affected systems. Maintenance costs dropped by 40% because technicians no longer needed emergency call-outs. The simple DIN rail mounting and small footprint allowed easy retrofitting into existing cabinets without redesign.
Key Takeaways
This case demonstrates the value of investing in redundant power architectures for critical industrial systems. The ABB SS822 provides a cost-effective, easy-to-deploy solution for eliminating single points of failure. When selecting a voting unit, ensure it matches your system's voltage and current requirements. The SS822's 24V DC input and 20A output cover many common control applications. Contact CtrlTechDaily to discuss how SS822 can solve your specific challenges.
Frequently Asked Questions
What types of applications is the SS822 best suited for?
The SS822 is ideal for any application requiring redundant 24V DC power for critical loads. Typical uses include PLC power supplies, safety systems, and process control cabinets. The unit handles up to 20A output current, making it suitable for medium-sized control panels. The supervised inputs ensure immediate notification of power supply issues.
How long does it take to deploy the SS822?
Deployment is quick due to the DIN rail mounting and compact 50 mm width. Most installations take less than an hour per unit. No special software or configuration is required. The unit works with standard SD821/822/823 power supplies, simplifying integration. Maintenance teams can complete the installation during a scheduled shutdown.
What support does CtrlTechDaily provide during implementation?
CtrlTechDaily offers pre-sales consultation to help select the right components for your system. Our technical team provides wiring diagrams and application notes. We also offer post-sale support for troubleshooting and system optimization. Contact us for pricing and availability.
