ABB SR511 3BSE000863R1 SR511 Regulator 24V/5V

ABB SR511 3BSE000863R1 SR511 Regulator 24V/5V

Core attributes

Product type: Industrial grade dual output linear regulator (belonging to ABB Advant OCS system supporting power module, focusing on high-precision power supply requirements of controller and peripheral modules, with low ripple and high anti-interference characteristics, suitable for core equipment power supply scenarios in the industrial control field)

Model identification: SR511 3BSE000863R1 ("SR" is the series code, representing a stable regulator; 511 "is a specification code that distinguishes between output voltage combinations and power levels; 3BSE000863R1 "is the ABB standard order number, and" R1 "represents the first version of the hardware design

Physical specifications: Adopting a 3U rack mounted design, the dimensions are 482.6mm (width, compatible with 19 inch standard cabinets) × 101.6mm (height) × 220mm (depth), with a net weight of 2.8kg, supporting DIN rail or bolt fixation, and can be installed on the same rack as T-1521Z controller and DSDP140B counter board, saving control cabinet space.

Key electrical and performance parameters

input parameters

AC 100-240V (wide input), frequency 50/60Hz, input current 1.5A (at 220V), power factor ≥ 0.9

Adapt to global industrial power grid standards without the need for additional transformers. Equipped with an EMC filter on the input side, it can withstand voltage fluctuations in the power grid (stable output within ± 20% range)

output parameters

Dual independent output: ① 24V DC, rated current 2A, maximum current 3A; ② 5V DC, rated current 3A, maximum current 4A

Output voltage accuracy ± 0.5% (24V output error ≤ 120mV, 5V output error ≤ 25mV), ripple voltage ≤ 50mV (peak to peak), meeting the power supply requirements of high-precision modules

Regulation and protection functions

Built in voltage regulation circuit (response time ≤ 100 μ s), overcurrent protection (triggered by 24V 3.5A, 5V 4.5A), overvoltage protection (triggered by 24V 28V, 5V 5.8V), short circuit protection (continuous short circuit self recovery)

The voltage regulation circuit can compensate for voltage drops caused by load changes in real time, and the overcurrent/overvoltage protection action time is ≤ 1ms to avoid damage to downstream modules

Environment and reliability

Working temperature 0-60 ℃, humidity 5% -95% (no condensation), protection level IP20, MTBF (mean time between failures) ≥ 100000 hours

Adopting industrial grade capacitors and rectifier bridges, selecting high-temperature resistant components (working temperature -40 ℃ to 125 ℃), and adapting to long-term operation in a sealed environment inside the control cabinet

Core functions and technological advantages

1. High precision power regulation and stable output

Dual independent voltage regulation design: The 24V and 5V output circuits use separate voltage regulation chips (LM25008 for 24V and LM2596-5.0 for 5V), combined with a 0.1% precision sampling resistor and high-speed operational amplifier, to achieve fast voltage compensation when the load changes. When the current of the DSDP140B counting board suddenly increases from 0.5A to 1.5A due to high-frequency counting, the 24V output voltage fluctuation is ≤ 50mV, ensuring that the counting accuracy is not affected by power supply fluctuations.

Low ripple anti-interference processing: The output side adopts a two-stage filtering circuit (first stage electrolytic capacitor+first stage ceramic capacitor), combined with a shielded transformer design, to control the ripple voltage below 50mV and avoid electromagnetic interference on the high-frequency counting signal of DSDP140B; The input side is equipped with an IEC 61000-4-5 level surge protector, which can withstand 2kV common mode surge impact and adapt to harsh environments in the power grid.

Wide load adaptability: Supports 0-100% load changes (such as a sudden increase in current from 0.3A to 1.2A when the T-1521Z controller starts), with a voltage regulation rate of ≤ 0.2%, without the need for additional load balancing resistors, reducing system power consumption; Equipped with soft start function, the starting impulse current is ≤ 1.2 times the rated current, avoiding impact on the upstream power switch.

2. Comprehensive security protection and status monitoring

Multi level protection mechanism: In addition to basic overcurrent, overvoltage, and short-circuit protection, it also has built-in overheat protection (automatic derating output when radiator temperature ≥ 85 ℃, output shutdown when ≥ 100 ℃), reverse connection protection (no output when input positive and negative poles are reversed, no component damage), forming a full chain protection of "prevention response fault tolerance"; Short circuit protection adopts a self recovery design, which automatically restores output after troubleshooting without the need for manual restart.

Visual status monitoring: Equipped with 2 LED indicator lights on the front (corresponding to 24V and 5V outputs respectively), green constant light indicates normal output, flashing indicates overload and derating, and off indicates no output or fault; Reserve fault signal output terminals (dry contacts) that can be connected to the DI channel of T-1521Z to achieve remote alarm and interlock control of power failures (such as triggering equipment emergency shutdown in case of power failure).

Redundancy expansion capability: Supports parallel redundant operation of 2 SR511 modules (with redundant current sharing boards required), with a current sharing error of ≤ 5%. When the main module fails, the backup module seamlessly switches (switching time ≤ 10ms), meeting the "zero interruption" power supply requirements of key scenarios such as petrochemicals; It can work in conjunction with ABB SD850 redundant power modules to form a "dual level redundant" power supply architecture.

3. Industrial compatibility and deployment flexibility

Multi device adaptation capability: 24V output can directly supply power to devices such as T-1521Z controller, DSDP140B counting board, AI890 analog input module, etc; The 5V output can be adapted to low-voltage equipment such as PLC core boards and communication modules, without the need for additional DC-DC converters, simplifying the system power supply architecture; The output terminal adopts a spring type wiring terminal, supporting 1-4mm ² wire connection, and the wiring firmness is better than traditional screw terminals.

Flexible installation and wiring: compatible with both 3U standard rack and DIN rail installation methods, and can be flexibly deployed according to the control cabinet space; The input and output cables can be separated for wiring (input cables go through power cable trays, output cables go through signal cable trays), with strong and weak current separation design to avoid interference from the input side being transmitted to the output side; It is recommended to use shielded twisted pair cables for output cables, with the shielding layer grounded at one end (grounding resistance ≤ 4 Ω) to further reduce interference.

Low maintenance design: adopting a fanless natural heat dissipation design (through large-area aluminum heat sinks) to reduce mechanical failure points; Select long-life models (rated life ≥ 50000 hours @ 40 ℃) for key components such as capacitors and voltage regulators, and reduce replacement frequency; Reserved heat dissipation holes on the front, no additional heat dissipation space needs to be reserved, suitable for high-density control cabinet deployment.

Selection and maintenance precautions

1. Key indicators for selection

Load power matching: Calculate the total power consumption of downstream devices (such as T-1521Z power consumption of 35W+SDP140B power consumption of 15W+other module power consumption of 20W, total power consumption of 70W). The 24V output needs to meet the current requirement of ≥ 70W/24V ≈ 2.92A. At this time, SR511 (24V maximum 3A) or upgrade to SR521 (24V maximum 5A) should be selected; When the total current of the 5V load exceeds 4A, an additional independent 5V power module needs to be configured.

Environmental and reliability requirements: Standard version SR511 is selected for ordinary industrial environments (0-50 ℃, no condensation); High temperature environment (50-60 ℃) requires the use of high-temperature enhanced version (with added cooling fan); Key scenarios such as nuclear power and chemical engineering require redundant operation and the integration of fault monitoring circuits into the control system.

Redundancy and expansion requirements: Single deployment is sufficient when redundancy is not required; When redundant power supply is required, ensure that the two module models and firmware versions are consistent, and configure original redundant current sharing boards; When expanding the load in the future, a 30% power margin should be reserved (if it is expected that the load current will increase by 0.8A in the future, the current selection should be based on 3A+0.8A=3.8A, and a larger power module should be selected).

2. Maintenance and troubleshooting

Regular maintenance procedure: Clean the radiator dust every month (blow with compressed air, pressure ≤ 0.3MPa), check the status of the LED indicator light and the tightness of the wiring terminals; Quarterly measurement of output voltage accuracy (tested with a four and a half digit multimeter, 24V output should be between 23.88-24.12V, 5V output should be between 4.975-5.025V); Replace the input side fuse tube annually (using the same specifications of slow melting fuse tube) and check for any bulging or leakage of the internal capacitor.

Common troubleshooting

24V output with no voltage (indicator light off)

Input power loss, fuse burnt out, overheating protection triggered

1. Measure the input terminal voltage to ensure that 100-240V is normal; 2. Check the input fuse (located at the bottom of the module), and replace it with a fuse of the same specification if it burns out; 3. Wait for the radiator to cool down to below 60 ℃ and observe if the output is restored

Large output voltage deviation (over ± 1%)

Overloading, aging of sampling resistors, and failure of filtering capacitors

1. Measure the output current and confirm that it does not exceed the rated value; 2. Open the module casing and replace the aging sampling resistor (with an accuracy of 0.1%); 3. Replace the output side filtering capacitor (recommended to use Nichicon brand)

Fault light flashing (overload derating)

Excessive load current, poor heat dissipation, and blocked ventilation

1. Check if downstream equipment is short circuited (such as DSDP140B output terminal short circuited); 2. Clean the dust from the radiator and ensure good ventilation in the control cabinet; 3. Reduce non core loads or replace with larger power modules

Excessive ripple (>100mV)

Filter capacitor failure, input power interference, non-standard wiring

1. Replace the output side filtering capacitor; 2. Install an EMC filter on the input side; 3. Reconnect the wiring to ensure that the output cable is far away from the power line and the shielding layer is grounded at one end