3BDM000199R1 | ABB SB 808F Lithium Battery for AC 800F RAM Buffering
3BDM000199R1 | ABB SB 808F Lithium Battery for AC 800F RAM Buffering
Manufacturer: ABB
Product No.: 3BDM000199R1
Condition:1000 in stock
Product Type: Lithium Battery
Product Origin: 3000199000016
Payment: T/T, Western Union
Weight: 20g
Shipping port: Xiamen
Warranty: 12 months
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ABB SB 808F Lithium Battery Pack - Critical Memory Protection for AC 800F Controllers
The ABB SB 808F (Part Number: 3BDM000199R1) is a precision-engineered lithium battery pack designed exclusively for RAM buffering and non-volatile variable retention in ABB AC 800F field controllers. This 2-piece battery set ensures uninterrupted data preservation during power interruptions, protecting critical process parameters, application logic, and system configurations from loss in safety-instrumented systems and process automation environments.
Product Identification & Specifications
| Specification | Details |
|---|---|
| ABB Part Number | 3BDM000199R1 |
| Type Designation | SB 808F |
| Alternative Designation | DSU 08 (functionally identical) |
| Package Contents | 2 lithium battery cells |
| Battery Chemistry | Lithium primary cell (non-rechargeable) |
| Nominal Voltage | 3.0 VDC per cell |
| Capacity (typical) | 950 mAh @ 20°C |
| Operating Temperature | -40°C to +85°C (storage and operation) |
| Expected Service Life | 5-10 years (depending on ambient temperature and load) |
| Dimensions (L×W×H) | 26 mm × 15 mm × 15 mm per cell |
| Net Weight | 0.02 kg (20 grams for 2-piece set) |
| Product Category | Control System Accessory / Backup Power |
System Compatibility & Application
Primary Application: AC 800F Controller Family
The SB 808F battery pack is specifically designed for the following ABB AC 800F field controller models:
- PM 802F: Compact field controller with 2 MB application memory
- PM 803F: Standard field controller with 16 MB application memory
- PM 805F: Advanced field controller with 32 MB application memory
- PM 806F: High-performance field controller with 64 MB application memory
Functional Purpose
These lithium cells serve two critical functions within AC 800F controllers:
- RAM Buffering: Maintains volatile RAM contents during power loss or controller shutdown, preserving application variables, process data, and runtime parameters for up to 30 days without external power.
- Non-Volatile Variable Storage: Powers the real-time clock (RTC) and retains user-defined non-volatile variables that must persist across power cycles, ensuring seamless process continuity after planned or unplanned outages.
Installation Location
The battery pack installs in a dedicated battery holder on the AC 800F controller base unit, accessible via a front-panel compartment. No tools are required for replacement—batteries snap into spring-loaded contacts with correct polarity enforcement to prevent reverse installation.
Regulatory Compliance & Shipping Classification
Customs & Trade Classification
| Classification Type | Code/Details |
|---|---|
| HS Code (Harmonized System) | 850650 - Primary cells and primary batteries, lithium |
| Customs Tariff Number | 85065010 |
| Country of Origin | United States (USA) |
Dangerous Goods Classification
As lithium primary batteries, the SB 808F is classified as dangerous goods for transportation purposes:
| Regulation | Classification |
|---|---|
| UN Number | UN3090 (Lithium metal batteries) |
| Packing Instruction | PI968 (IATA Dangerous Goods Regulations) |
| Hazard Class | Class 9 - Miscellaneous Dangerous Substances and Articles |
| Shipping Label Required | Yes - Class 9 hazard label and lithium battery handling label |
| Air Transport Restrictions | Passenger aircraft: Forbidden / Cargo aircraft: Allowed with restrictions |
Environmental Compliance
| Standard | Status |
|---|---|
| RoHS Directive 2011/65/EU | Not RoHS Compliant (lithium batteries exempt under Annex III) |
| WEEE Directive 2012/19/EU | Product not in WEEE scope (component-level battery) |
| REACH Regulation (EC) 1907/2006 | No SVHC (Substances of Very High Concern) present |
| SCIP Database (Germany) | Registered - No hazardous substances above threshold |
| Battery Directive 2006/66/EC | Compliant - Industrial battery, requires proper disposal |
Why Battery Replacement is Critical
Consequences of Battery Depletion
When SB 808F batteries reach end-of-life, the following issues may occur:
- Data Loss: Application variables, process setpoints, and accumulated totals stored in RAM will be lost during power interruptions or controller restarts
- Configuration Reset: User-defined non-volatile variables may revert to default values, requiring manual reconfiguration
- Time/Date Loss: Real-time clock will reset to factory default (typically January 1, 2000), causing timestamp errors in event logs and alarms
- Process Disruption: Safety systems may require re-validation after data loss, leading to unplanned downtime and production delays
- Regulatory Non-Compliance: Industries governed by 21 CFR Part 11, IEC 61511, or ISO 13849 may face audit findings if critical data is not properly retained
Battery Life Expectancy Factors
The SB 808F battery lifespan varies based on operating conditions:
| Ambient Temperature | Expected Lifespan |
|---|---|
| +25°C (77°F) | 8-10 years (optimal conditions) |
| +40°C (104°F) | 5-7 years (typical industrial environment) |
| +55°C (131°F) | 3-5 years (high-temperature applications) |
| +70°C (158°F) | 2-3 years (extreme conditions, near controller limits) |
Note: Frequent power cycling and high RAM usage may reduce battery life. ABB recommends proactive replacement every 5 years regardless of battery status indicator.
Installation & Replacement Procedure
Pre-Replacement Checklist
- Backup Application: Download current controller application and configuration to engineering station using Control Builder F software
- Document Settings: Record all non-volatile variable values and process parameters that may be affected
- Schedule Downtime: Plan replacement during scheduled maintenance window or process shutdown (hot-swap not recommended)
- Verify Part Number: Confirm replacement batteries are genuine ABB 3BDM000199R1 (counterfeit batteries may cause controller malfunction)
- ESD Precautions: Use anti-static wrist strap when handling controller electronics
Step-by-Step Replacement (Recommended Method)
- Power Down Controller: Safely shut down AC 800F controller via Control Builder F or local HMI. Wait for all LEDs to extinguish (approximately 30 seconds).
- Disconnect Power: Remove 24 VDC power supply connection from controller base unit. Verify voltage absence with multimeter.
- Access Battery Compartment: Open front-panel battery cover by pressing release tab (no screwdriver required on most models).
- Remove Old Batteries: Gently pull battery holder outward. Note polarity markings (+ and - symbols). Remove both cells from holder.
- Inspect Contacts: Check battery contacts for corrosion or debris. Clean with isopropyl alcohol and lint-free cloth if necessary.
- Install New Batteries: Insert new SB 808F cells into holder, observing correct polarity. Ensure cells are fully seated in spring contacts.
- Reinstall Holder: Slide battery holder back into controller until it clicks into place. Close battery compartment cover.
- Restore Power: Reconnect 24 VDC power supply. Controller will perform self-test (approximately 15-20 seconds).
- Verify Operation: Check controller status LEDs. Green RUN LED should illuminate. Battery status indicator should show OK (not low battery warning).
- Restore Application: If application was lost, download backup from Control Builder F. Verify all non-volatile variables and process parameters.
- Document Replacement: Record battery replacement date, serial number (if available), and next scheduled replacement date in maintenance log.
Hot-Swap Procedure (Advanced Users Only)
For critical applications where downtime is unacceptable, experienced technicians may perform battery replacement with controller powered:
- Time Limit: Complete replacement within 60 seconds to prevent RAM data loss
- Risk: Accidental short-circuit or contact bounce may cause controller reset
- Recommendation: ABB does not officially support hot-swap. Use only if process cannot be interrupted and backup is current.
Battery Status Monitoring & Diagnostics
Controller Battery Status Indicators
AC 800F controllers provide multiple methods to monitor battery health:
| Monitoring Method | Description |
|---|---|
| Front Panel LED | Dedicated battery status LED: Green = OK, Amber = Low, Red = Replace immediately |
| Control Builder F | System diagnostics display battery voltage and estimated remaining life percentage |
| OPC Server | Battery status available as OPC tag for SCADA integration and alarm generation |
| Event Log | Controller logs battery low warnings and critical alerts with timestamp |
Interpreting Battery Voltage Readings
| Voltage Range | Status | Action Required |
|---|---|---|
| 2.7 - 3.0 VDC | Good | No action - battery healthy |
| 2.5 - 2.7 VDC | Fair | Plan replacement within 6 months |
| 2.3 - 2.5 VDC | Low | Replace within 30 days |
| Below 2.3 VDC | Critical | Replace immediately - data loss risk |
Common Battery-Related Fault Codes
| Fault Code | Description | Resolution |
|---|---|---|
| BAT_LOW | Battery voltage below threshold | Replace batteries within 30 days |
| BAT_FAIL | Battery circuit fault or missing battery | Check battery installation, replace if damaged |
| RTC_LOST | Real-time clock reset due to battery depletion | Replace batteries and reset clock via Control Builder F |
| NV_VAR_LOST | Non-volatile variables lost | Replace batteries and restore variable values from backup |
Safety & Handling Instructions
Lithium Battery Safety Precautions
- Do Not Recharge: SB 808F cells are non-rechargeable lithium primary batteries. Attempting to recharge will cause overheating, venting, or fire.
- Avoid Short Circuit: Keep batteries away from conductive materials (coins, keys, tools). Short-circuit can cause rapid heating and potential fire hazard.
- Temperature Limits: Do not expose to temperatures above +85°C or below -40°C. Extreme heat may cause thermal runaway.
- No Disassembly: Never puncture, crush, or disassemble battery cells. Internal lithium metal reacts violently with moisture.
- Fire Suppression: In case of lithium battery fire, use Class D fire extinguisher or dry sand. Water will intensify lithium fires.
- Ventilation: If battery vents or leaks, evacuate area and provide ventilation. Lithium battery electrolyte is corrosive and toxic.
Storage Recommendations
- Store in original packaging in cool, dry location (15-25°C optimal)
- Keep away from heat sources, direct sunlight, and flammable materials
- Shelf life: 10 years from manufacture date when stored properly
- Inspect packaging for damage before use—do not use if package is compromised
Disposal & Recycling
Lithium batteries must be disposed of according to local regulations and EU Battery Directive 2006/66/EC:
- Do Not Discard in General Waste: Lithium batteries are hazardous waste and must be recycled
- Recycling Centers: Return to ABB service center, authorized battery recycler, or municipal hazardous waste facility
- Tape Terminals: Before disposal, cover battery terminals with insulating tape to prevent short-circuit during transport
- Bulk Disposal: For large quantities, contact specialized lithium battery recycling companies (e.g., Call2Recycle, Umicore)
Procurement & Inventory Management
Recommended Spare Parts Strategy
For facilities operating multiple AC 800F controllers, maintain strategic battery inventory:
| Number of Controllers | Recommended Spare Batteries |
|---|---|
| 1-5 controllers | 1 set (2 cells) on-site |
| 6-20 controllers | 2-3 sets on-site |
| 21-50 controllers | 5-7 sets on-site |
| 50+ controllers | 10% of installed base as spares |
Preventive Maintenance Schedule
- Annual Inspection: Check battery status indicators during yearly controller maintenance
- 5-Year Replacement: Proactively replace all batteries every 5 years regardless of status (best practice for safety systems)
- Temperature Monitoring: In high-temperature environments (>40°C), inspect batteries every 6 months
- Documentation: Maintain battery replacement log with dates, part numbers, and technician signatures for audit compliance
Genuine vs. Aftermarket Batteries
Warning: Only use genuine ABB 3BDM000199R1 batteries. Aftermarket or generic lithium cells may:
- Have incorrect voltage characteristics causing premature controller shutdown
- Lack proper safety certifications (UN3090, UL recognition)
- Void ABB controller warranty if non-genuine parts cause failure
- Fail prematurely due to inferior quality control
Technical Documentation & Support
Available Documentation
- Product Datasheet: Electrical specifications, dimensions, and compliance certifications
- AC 800F Hardware Manual: Controller installation guide with battery replacement procedures (Document ID: 3BSE020923)
- Control Builder F User Guide: Software instructions for battery status monitoring and diagnostics
- Safety Data Sheet (SDS): Lithium battery hazard information and emergency response procedures
- UN3090 Transport Certificate: Dangerous goods shipping documentation for logistics compliance
Engineering Support
For technical assistance with battery replacement, controller diagnostics, or application-specific questions:
- ABB Technical Support Portal: new.abb.com/service
- Control Systems Hotline: Available 24/7 for critical process issues
- Local ABB Service Center: On-site support and certified technician dispatch
- Control Builder F Online Help: Context-sensitive battery diagnostics guidance
Industry Application Examples
Oil & Gas: Offshore Platform SIS
A North Sea offshore platform uses 12 AC 800F controllers for safety instrumented systems (SIS) managing emergency shutdown valves and fire & gas detection. Battery replacement is performed during annual turnarounds, with all 12 sets replaced simultaneously to maintain consistent maintenance records for IEC 61511 compliance audits.
Chemical Processing: Batch Reactor Control
A specialty chemicals plant operates AC 800F controllers for batch recipe management. Non-volatile variables store critical recipe parameters (temperatures, pressures, ingredient ratios). After a battery depletion incident caused recipe data loss and a $50,000 batch rejection, the plant implemented a 4-year proactive battery replacement program with quarterly voltage monitoring.
Water Treatment: SCADA Integration
A municipal water treatment facility uses AC 800F controllers networked to a central SCADA system. Battery status is monitored via OPC tags, triggering automatic work orders in the CMMS when voltage drops below 2.6 VDC. This predictive approach has eliminated unplanned battery-related downtime over 5 years of operation.
Pharmaceutical: FDA-Regulated Manufacturing
A pharmaceutical manufacturer subject to 21 CFR Part 11 maintains detailed battery replacement logs as part of their electronic records system. All battery changes are documented with date, time, technician signature, and before/after voltage readings. Batteries are replaced every 5 years regardless of status to ensure data integrity for FDA inspections.
Warranty & Product Authenticity
Manufacturer Warranty
ABB SB 808F batteries are covered by ABB's standard warranty terms:
- Warranty Period: 12 months from date of purchase or 18 months from manufacture date, whichever occurs first
- Coverage: Defects in materials and workmanship under normal use and storage conditions
- Exclusions: Batteries damaged by improper installation, exposure to extreme temperatures, or use beyond rated lifespan
- Claims Process: Contact ABB service center with proof of purchase and description of defect
Authenticity Verification
Ensure you receive genuine ABB batteries by checking:
- ABB logo and part number (3BDM000199R1) printed on battery label
- Manufacture date code and batch number on packaging
- Holographic security label on retail packaging (if applicable)
- Purchase from authorized ABB distributors or Industrial Control Hub
Product Description
ABB SB 808F Lithium Battery Pack - Critical Memory Protection for AC 800F Controllers
The ABB SB 808F (Part Number: 3BDM000199R1) is a precision-engineered lithium battery pack designed exclusively for RAM buffering and non-volatile variable retention in ABB AC 800F field controllers. This 2-piece battery set ensures uninterrupted data preservation during power interruptions, protecting critical process parameters, application logic, and system configurations from loss in safety-instrumented systems and process automation environments.
Product Identification & Specifications
| Specification | Details |
|---|---|
| ABB Part Number | 3BDM000199R1 |
| Type Designation | SB 808F |
| Alternative Designation | DSU 08 (functionally identical) |
| Package Contents | 2 lithium battery cells |
| Battery Chemistry | Lithium primary cell (non-rechargeable) |
| Nominal Voltage | 3.0 VDC per cell |
| Capacity (typical) | 950 mAh @ 20°C |
| Operating Temperature | -40°C to +85°C (storage and operation) |
| Expected Service Life | 5-10 years (depending on ambient temperature and load) |
| Dimensions (L×W×H) | 26 mm × 15 mm × 15 mm per cell |
| Net Weight | 0.02 kg (20 grams for 2-piece set) |
| Product Category | Control System Accessory / Backup Power |
System Compatibility & Application
Primary Application: AC 800F Controller Family
The SB 808F battery pack is specifically designed for the following ABB AC 800F field controller models:
- PM 802F: Compact field controller with 2 MB application memory
- PM 803F: Standard field controller with 16 MB application memory
- PM 805F: Advanced field controller with 32 MB application memory
- PM 806F: High-performance field controller with 64 MB application memory
Functional Purpose
These lithium cells serve two critical functions within AC 800F controllers:
- RAM Buffering: Maintains volatile RAM contents during power loss or controller shutdown, preserving application variables, process data, and runtime parameters for up to 30 days without external power.
- Non-Volatile Variable Storage: Powers the real-time clock (RTC) and retains user-defined non-volatile variables that must persist across power cycles, ensuring seamless process continuity after planned or unplanned outages.
Installation Location
The battery pack installs in a dedicated battery holder on the AC 800F controller base unit, accessible via a front-panel compartment. No tools are required for replacement—batteries snap into spring-loaded contacts with correct polarity enforcement to prevent reverse installation.
Regulatory Compliance & Shipping Classification
Customs & Trade Classification
| Classification Type | Code/Details |
|---|---|
| HS Code (Harmonized System) | 850650 - Primary cells and primary batteries, lithium |
| Customs Tariff Number | 85065010 |
| Country of Origin | United States (USA) |
Dangerous Goods Classification
As lithium primary batteries, the SB 808F is classified as dangerous goods for transportation purposes:
| Regulation | Classification |
|---|---|
| UN Number | UN3090 (Lithium metal batteries) |
| Packing Instruction | PI968 (IATA Dangerous Goods Regulations) |
| Hazard Class | Class 9 - Miscellaneous Dangerous Substances and Articles |
| Shipping Label Required | Yes - Class 9 hazard label and lithium battery handling label |
| Air Transport Restrictions | Passenger aircraft: Forbidden / Cargo aircraft: Allowed with restrictions |
Environmental Compliance
| Standard | Status |
|---|---|
| RoHS Directive 2011/65/EU | Not RoHS Compliant (lithium batteries exempt under Annex III) |
| WEEE Directive 2012/19/EU | Product not in WEEE scope (component-level battery) |
| REACH Regulation (EC) 1907/2006 | No SVHC (Substances of Very High Concern) present |
| SCIP Database (Germany) | Registered - No hazardous substances above threshold |
| Battery Directive 2006/66/EC | Compliant - Industrial battery, requires proper disposal |
Why Battery Replacement is Critical
Consequences of Battery Depletion
When SB 808F batteries reach end-of-life, the following issues may occur:
- Data Loss: Application variables, process setpoints, and accumulated totals stored in RAM will be lost during power interruptions or controller restarts
- Configuration Reset: User-defined non-volatile variables may revert to default values, requiring manual reconfiguration
- Time/Date Loss: Real-time clock will reset to factory default (typically January 1, 2000), causing timestamp errors in event logs and alarms
- Process Disruption: Safety systems may require re-validation after data loss, leading to unplanned downtime and production delays
- Regulatory Non-Compliance: Industries governed by 21 CFR Part 11, IEC 61511, or ISO 13849 may face audit findings if critical data is not properly retained
Battery Life Expectancy Factors
The SB 808F battery lifespan varies based on operating conditions:
| Ambient Temperature | Expected Lifespan |
|---|---|
| +25°C (77°F) | 8-10 years (optimal conditions) |
| +40°C (104°F) | 5-7 years (typical industrial environment) |
| +55°C (131°F) | 3-5 years (high-temperature applications) |
| +70°C (158°F) | 2-3 years (extreme conditions, near controller limits) |
Note: Frequent power cycling and high RAM usage may reduce battery life. ABB recommends proactive replacement every 5 years regardless of battery status indicator.
Installation & Replacement Procedure
Pre-Replacement Checklist
- Backup Application: Download current controller application and configuration to engineering station using Control Builder F software
- Document Settings: Record all non-volatile variable values and process parameters that may be affected
- Schedule Downtime: Plan replacement during scheduled maintenance window or process shutdown (hot-swap not recommended)
- Verify Part Number: Confirm replacement batteries are genuine ABB 3BDM000199R1 (counterfeit batteries may cause controller malfunction)
- ESD Precautions: Use anti-static wrist strap when handling controller electronics
Step-by-Step Replacement (Recommended Method)
- Power Down Controller: Safely shut down AC 800F controller via Control Builder F or local HMI. Wait for all LEDs to extinguish (approximately 30 seconds).
- Disconnect Power: Remove 24 VDC power supply connection from controller base unit. Verify voltage absence with multimeter.
- Access Battery Compartment: Open front-panel battery cover by pressing release tab (no screwdriver required on most models).
- Remove Old Batteries: Gently pull battery holder outward. Note polarity markings (+ and - symbols). Remove both cells from holder.
- Inspect Contacts: Check battery contacts for corrosion or debris. Clean with isopropyl alcohol and lint-free cloth if necessary.
- Install New Batteries: Insert new SB 808F cells into holder, observing correct polarity. Ensure cells are fully seated in spring contacts.
- Reinstall Holder: Slide battery holder back into controller until it clicks into place. Close battery compartment cover.
- Restore Power: Reconnect 24 VDC power supply. Controller will perform self-test (approximately 15-20 seconds).
- Verify Operation: Check controller status LEDs. Green RUN LED should illuminate. Battery status indicator should show OK (not low battery warning).
- Restore Application: If application was lost, download backup from Control Builder F. Verify all non-volatile variables and process parameters.
- Document Replacement: Record battery replacement date, serial number (if available), and next scheduled replacement date in maintenance log.
Hot-Swap Procedure (Advanced Users Only)
For critical applications where downtime is unacceptable, experienced technicians may perform battery replacement with controller powered:
- Time Limit: Complete replacement within 60 seconds to prevent RAM data loss
- Risk: Accidental short-circuit or contact bounce may cause controller reset
- Recommendation: ABB does not officially support hot-swap. Use only if process cannot be interrupted and backup is current.
Battery Status Monitoring & Diagnostics
Controller Battery Status Indicators
AC 800F controllers provide multiple methods to monitor battery health:
| Monitoring Method | Description |
|---|---|
| Front Panel LED | Dedicated battery status LED: Green = OK, Amber = Low, Red = Replace immediately |
| Control Builder F | System diagnostics display battery voltage and estimated remaining life percentage |
| OPC Server | Battery status available as OPC tag for SCADA integration and alarm generation |
| Event Log | Controller logs battery low warnings and critical alerts with timestamp |
Interpreting Battery Voltage Readings
| Voltage Range | Status | Action Required |
|---|---|---|
| 2.7 - 3.0 VDC | Good | No action - battery healthy |
| 2.5 - 2.7 VDC | Fair | Plan replacement within 6 months |
| 2.3 - 2.5 VDC | Low | Replace within 30 days |
| Below 2.3 VDC | Critical | Replace immediately - data loss risk |
Common Battery-Related Fault Codes
| Fault Code | Description | Resolution |
|---|---|---|
| BAT_LOW | Battery voltage below threshold | Replace batteries within 30 days |
| BAT_FAIL | Battery circuit fault or missing battery | Check battery installation, replace if damaged |
| RTC_LOST | Real-time clock reset due to battery depletion | Replace batteries and reset clock via Control Builder F |
| NV_VAR_LOST | Non-volatile variables lost | Replace batteries and restore variable values from backup |
Safety & Handling Instructions
Lithium Battery Safety Precautions
- Do Not Recharge: SB 808F cells are non-rechargeable lithium primary batteries. Attempting to recharge will cause overheating, venting, or fire.
- Avoid Short Circuit: Keep batteries away from conductive materials (coins, keys, tools). Short-circuit can cause rapid heating and potential fire hazard.
- Temperature Limits: Do not expose to temperatures above +85°C or below -40°C. Extreme heat may cause thermal runaway.
- No Disassembly: Never puncture, crush, or disassemble battery cells. Internal lithium metal reacts violently with moisture.
- Fire Suppression: In case of lithium battery fire, use Class D fire extinguisher or dry sand. Water will intensify lithium fires.
- Ventilation: If battery vents or leaks, evacuate area and provide ventilation. Lithium battery electrolyte is corrosive and toxic.
Storage Recommendations
- Store in original packaging in cool, dry location (15-25°C optimal)
- Keep away from heat sources, direct sunlight, and flammable materials
- Shelf life: 10 years from manufacture date when stored properly
- Inspect packaging for damage before use—do not use if package is compromised
Disposal & Recycling
Lithium batteries must be disposed of according to local regulations and EU Battery Directive 2006/66/EC:
- Do Not Discard in General Waste: Lithium batteries are hazardous waste and must be recycled
- Recycling Centers: Return to ABB service center, authorized battery recycler, or municipal hazardous waste facility
- Tape Terminals: Before disposal, cover battery terminals with insulating tape to prevent short-circuit during transport
- Bulk Disposal: For large quantities, contact specialized lithium battery recycling companies (e.g., Call2Recycle, Umicore)
Procurement & Inventory Management
Recommended Spare Parts Strategy
For facilities operating multiple AC 800F controllers, maintain strategic battery inventory:
| Number of Controllers | Recommended Spare Batteries |
|---|---|
| 1-5 controllers | 1 set (2 cells) on-site |
| 6-20 controllers | 2-3 sets on-site |
| 21-50 controllers | 5-7 sets on-site |
| 50+ controllers | 10% of installed base as spares |
Preventive Maintenance Schedule
- Annual Inspection: Check battery status indicators during yearly controller maintenance
- 5-Year Replacement: Proactively replace all batteries every 5 years regardless of status (best practice for safety systems)
- Temperature Monitoring: In high-temperature environments (>40°C), inspect batteries every 6 months
- Documentation: Maintain battery replacement log with dates, part numbers, and technician signatures for audit compliance
Genuine vs. Aftermarket Batteries
Warning: Only use genuine ABB 3BDM000199R1 batteries. Aftermarket or generic lithium cells may:
- Have incorrect voltage characteristics causing premature controller shutdown
- Lack proper safety certifications (UN3090, UL recognition)
- Void ABB controller warranty if non-genuine parts cause failure
- Fail prematurely due to inferior quality control
Technical Documentation & Support
Available Documentation
- Product Datasheet: Electrical specifications, dimensions, and compliance certifications
- AC 800F Hardware Manual: Controller installation guide with battery replacement procedures (Document ID: 3BSE020923)
- Control Builder F User Guide: Software instructions for battery status monitoring and diagnostics
- Safety Data Sheet (SDS): Lithium battery hazard information and emergency response procedures
- UN3090 Transport Certificate: Dangerous goods shipping documentation for logistics compliance
Engineering Support
For technical assistance with battery replacement, controller diagnostics, or application-specific questions:
- ABB Technical Support Portal: new.abb.com/service
- Control Systems Hotline: Available 24/7 for critical process issues
- Local ABB Service Center: On-site support and certified technician dispatch
- Control Builder F Online Help: Context-sensitive battery diagnostics guidance
Industry Application Examples
Oil & Gas: Offshore Platform SIS
A North Sea offshore platform uses 12 AC 800F controllers for safety instrumented systems (SIS) managing emergency shutdown valves and fire & gas detection. Battery replacement is performed during annual turnarounds, with all 12 sets replaced simultaneously to maintain consistent maintenance records for IEC 61511 compliance audits.
Chemical Processing: Batch Reactor Control
A specialty chemicals plant operates AC 800F controllers for batch recipe management. Non-volatile variables store critical recipe parameters (temperatures, pressures, ingredient ratios). After a battery depletion incident caused recipe data loss and a $50,000 batch rejection, the plant implemented a 4-year proactive battery replacement program with quarterly voltage monitoring.
Water Treatment: SCADA Integration
A municipal water treatment facility uses AC 800F controllers networked to a central SCADA system. Battery status is monitored via OPC tags, triggering automatic work orders in the CMMS when voltage drops below 2.6 VDC. This predictive approach has eliminated unplanned battery-related downtime over 5 years of operation.
Pharmaceutical: FDA-Regulated Manufacturing
A pharmaceutical manufacturer subject to 21 CFR Part 11 maintains detailed battery replacement logs as part of their electronic records system. All battery changes are documented with date, time, technician signature, and before/after voltage readings. Batteries are replaced every 5 years regardless of status to ensure data integrity for FDA inspections.
Warranty & Product Authenticity
Manufacturer Warranty
ABB SB 808F batteries are covered by ABB's standard warranty terms:
- Warranty Period: 12 months from date of purchase or 18 months from manufacture date, whichever occurs first
- Coverage: Defects in materials and workmanship under normal use and storage conditions
- Exclusions: Batteries damaged by improper installation, exposure to extreme temperatures, or use beyond rated lifespan
- Claims Process: Contact ABB service center with proof of purchase and description of defect
Authenticity Verification
Ensure you receive genuine ABB batteries by checking:
- ABB logo and part number (3BDM000199R1) printed on battery label
- Manufacture date code and batch number on packaging
- Holographic security label on retail packaging (if applicable)
- Purchase from authorized ABB distributors or Industrial Control Hub