ABB DSSR122 48990001-NK

Product Overview

DSSR122 48990001-NK is a DC regulated Power supply unit specially designed by ABB for industrial control systems such as Advant Master process control system, Advant OCS, 800xA, etc. It belongs to the core power supply module of the Advant Power series. The exchange number is EXC48990001-NK. This module adopts a 24VDC input and 5VDC high-current regulated output architecture, mainly providing stable DC working power for core hardware such as ABB AC410 and AC450 series controllers, S100 I/O sub-racks, and DCN gateways. It serves as the power supply foundation for the entire automated control system.

Product functional features

(1) Core power supply function

1. High-precision voltage stabilization: Reduce the ripple coefficient to ensure the stable operation of precision electronic components such as controllers, logic chips, and I/O cards, and avoid program crashes and signal misreadings caused by voltage drift.

2. High current load capacity: With a rated output of 40A, it can meet the parallel power supply requirements of multiple modules. A single DSSR122 48990001-NK can simultaneously provide centralized power supply for one main controller and multiple I/O sub-racks, simplifying cabinet wiring.

3. Specialized system compatibility: Optimized for the hardware circuit of ABB Advant series controllers, the output voltage and timing are fully matched with the power-on logic of the original factory equipment, eliminating hardware damage caused by power-on timing errors.

(2) Multiple safety protection functions

1. Overload protection: When the output current exceeds the rated value, it automatically limits the current, triggers the fuse protection circuit, cuts off the abnormal output, and protects the back-end load and its own power devices.

2. Short-circuit protection: In the event of a short circuit in the back-end line, the output is quickly cut off to prevent the short-circuit current from burning out the controller's mainboard and terminal blocks. Once the fault is resolved, the operation can resume.

3. Reverse connection protection: When the positive and negative terminals of the input are mistakenly connected, the anti-reverse connection circuit inside the module blocks the circuit, preventing the power module and the front-end distribution equipment from being burned out and reducing the risk of on-site wiring errors.

4. Overheat protection: Built-in temperature detection element. When the temperature rise exceeds the standard due to long-term operation under high load, it will automatically reduce the power output or shut down the machine. When the temperature drops, it will automatically recover.

(3) Industrial environment adaptation features

1. Wide-temperature operation: Adapted to the conventional temperature environment of industrial control cabinets, it can operate continuously for a long time in non-constant-temperature scenarios such as workshops, power stations, and chemical plants.

2. Anti-interference design: It integrates an EMC electromagnetic filter circuit internally to resist electromagnetic interference generated by equipment such as frequency converters, relays, and motors, ensuring the purity of power supply.

3. Maintenance-free structure: Fully enclosed modular design, no exposed moving parts, no cooling fan, dust-proof

Common Issues and Solutions During Use

Based on field O&M experience and product specifications, the following is a summary of common faults, issues, and solutions for the DSSR122 (48990001-NK) during installation, operation, and maintenance:

(I) No output upon power-up; indicator lights off

Fault Symptom: The upstream 24VDC power supply is normal, but the module provides no 5V output, and the panel indicator lights are completely off.

Troubleshooting Causes:

• Loose input wiring or poor terminal contact;
• Blown internal dedicated fuse (5672827-20, 20A);
• Internal power component failure (caused by long-term overload).

Solutions:

• Disconnect power, retighten input terminals, and check for damaged cable insulation;
• Open the module's fuse compartment and replace the fuse with a spare of the same 20A specification (do not use a fuse rated higher than 20A);
• If there is still no output after replacing the fuse, the module hardware is deemed faulty; replace the entire unit.

(II) Frequent overload protection triggering and flashing alarm indicators during operation

Fault Symptom: The module triggers an alarm after operating for a period; 5V output is interrupted, recovers briefly after cooling down, and the issue recurs.

Troubleshooting Causes:

• Excessive downstream load; internal short circuit or leakage in downstream I/O modules or controllers;
• Poor cabinet ventilation, heavy dust accumulation on the module, and inadequate heat dissipation triggering overheat protection.

Solutions:

• Split the load by transferring some I/O racks to a backup power supply to reduce the load current on the individual DSSR122 (48990001-NK) unit;
• Disconnect downstream loads in sections to locate and replace the faulty card (short circuit/leakage);
• Clean dust from the module surface and cabinet interior; ensure unobstructed airflow at the front and rear of the cabinet and maintain an ambient temperature of 0–45°C.

(III) Module functions normally, but the controller repeatedly reboots

Fault Symptom: The power indicator is normal and the measured 5V output is correct, but the downstream AC410/AC450 controller frequently reboots and communication is interrupted. 

Troubleshooting Causes:

• Loose output terminal connections causing voltage drop during high-current operation;
• Module aging leading to increased output ripple, which interferes with the controller's logic circuitry;
• Electromagnetic crosstalk between multiple modules in the same rack.

Solutions

• Power down the unit and tighten all output terminals; verify that cable gauges meet the requirements for 40A high-current capacity;
• Measure output voltage ripple using a multimeter; replace the module if the ripple exceeds specifications;
• Route high-voltage/power lines separately from low-voltage/signal lines to avoid running power cables parallel to signal cables.

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