Application Scenarios:
Within the electrical cabinet of a water treatment plant’s control room, dozens of ABB AC 500 PLCs and remote I/O modules orchestrate the flow of chemicals and filtration cycles. A single point of failure in the 24VDC power rail could halt monitoring and control, risking process deviation. Here, two ABB NGPS-11 modules are configured in a parallel, redundant setup. They share the load seamlessly, powering the entire control system. If the primary unit fails due to a component issue or input surge, the secondary NGPS-11 instantly takes over the full load without any interruption to the downstream controllers. The integrated alarm contact immediately signals the fault to the SCADA system, allowing for planned maintenance. This setup ensures that the purification process continues uninterrupted, safeguarding both water quality and infrastructure, demonstrating how the NGPS-11 provides the resilient “heartbeat” for mission-critical automation.
Technical Principles and Innovative Values:
The ABB NGPS-11 is engineered for simplicity, reliability, and system integration in harsh industrial environments. Its design philosophy centers on delivering clean, stable power with maximum uptime.
Innovation Point 1: True Parallel Redundancy with Simple Wiring. Unlike basic power supplies that require complex external logic, the NGPS-11 is designed for straightforward N+1 redundancy. Its output circuit includes buffering and decoupling diodes, allowing multiple units to be directly connected in parallel. This design ensures that if one module fails, the other(s) can continue to supply the load without reverse current flow, enabling simple and cost-effective high-availability power systems.
Innovation Point 2: Wide-Range Input and Robust Design. The module accepts a broad input voltage range (100-240V AC), making it compatible with power grids worldwide without the need for taps or manual configuration. Built to withstand industrial environments, it features high efficiency, low heat dissipation, and high immunity to line-born interference, ensuring stable 24VDC output even in the presence of voltage sags or surges on the mains supply.
Innovation Point 3: Comprehensive Diagnostics and Serviceability. The NGPS-11 provides clear local diagnostics via LED status indicators for immediate visual health checks. Additionally, the “power good” signal from the alarm contact can be wired directly to a PLC input, enabling remote system-level monitoring of the power supply’s status. Its compact, DIN-rail format allows for easy installation and, in a redundant setup, permits the hot-swapping of a faulty unit without shutting down the controlled process.
Application Cases and Industry Value:
Case Study: Enhancing Uptime in an Automotive Manufacturing Line
A major automotive OEM experienced unplanned stoppages on a robotic welding line, traced to intermittent failures of a non-redundant, generic 24V power supply feeding the safety controller and network switches. Each stoppage resulted in over 30 minutes of production loss and required a technician for a hard reset.
The solution was to replace the single power supply with a redundant pair of ABB NGPS-11 modules in a decentralized cabinet on the line. The modules were paralleled as per the manual, creating a fault-tolerant power source. Six months post-installation, a voltage spike on the plant floor damaged one of the NGPS-11 units. As designed, the second module immediately supported the entire load. The line continued running without a pause, while the fault was silently signaled to the maintenance HMI. A technician replaced the failed module during the next scheduled break. The maintenance supervisor reported, “The ABB NGPS-11 setup turned a potential line-down event into a simple scheduled swap. The reliability it added for a minimal investment was outstanding. We’ve since standardized this redundant configuration for all critical cell controllers.”
Related Product Combination Solutions:
ABB CP-E 24/5.0: A compact power supply from the same family, suitable for lower power applications or distributed point-of-load power.
ABB PLCs (e.g., AC500 series): The primary controllers and I/O systems that are reliably powered by the NGPS-11.
ABB DIN-Rail Circuit Breakers (e.g., S200 series): Used upstream of the NGPS-11 for branch circuit protection and isolation.
ABB Buffer Modules (e.g., CP-U Buffer): Can be used in conjunction with the NGPS-11 to provide ride-through during brief power interruptions.
ABB System Pro M compact S200L DC-UPS: A complete uninterruptible power solution that can be integrated with the NGPS-11 for extended backup time during mains failure.
ABB 24VDC Relays and Interfaces: Field devices and interface modules that operate on the stable 24VDC provided by the NGPS-11.
ABB DIN-Rail Enclosures: Enclosures for mounting and protecting the NGPS-11 and associated components in industrial settings.
Installation, Maintenance, and Full-Cycle Support:
Installation of the ABB NGPS-11 is straightforward. Mount it securely on a standard DIN rail within the enclosure. Connect the AC line, neutral, and protective earth wires to the input terminals, and the DC output wires to the +/- output terminals. For redundant setups, connect the outputs of two units in parallel following the precise wiring diagram in the manual, ensuring the use of the recommended decoupling diodes if not internally integrated. The clear labeling and clamp-type terminals facilitate quick and error-free wiring.
Maintenance is minimal. Regular visual inspections for signs of overheating or dust accumulation are recommended. The status LEDs provide immediate operational feedback. In a redundant configuration, the health of each unit can be monitored remotely via its alarm contact. Should a unit fail, the modular DIN-rail design allows for rapid replacement: simply power down the individual unit (in a 1+1 setup, the other carries the load), release the tension clip, slide the unit off the rail, and replace it with a new one. No system shutdown is required.
We provide comprehensive support for the ABB NGPS-11 and associated power solutions, from initial system design and redundancy planning to technical consultation. We supply genuine, factory-fresh ABB components, guaranteeing performance, safety, and longevity. Our team can assist you in designing a robust power distribution architecture that ensures your control systems remain operational, maximizing plant productivity.
