PCS6000 system: ABB’s modular medium-voltage power conversion platform designed for high-power industrial drives (such as steel rolling, mining, and cement) and renewable energy (wind/solar). It supports a power range of 4-120 MVA and voltage levels from 10 kV to 230 kV. It utilizes IGCT/IGBT technology for bidirectional power flow and four-quadrant operation, and features dynamic reactive power compensation (20-100 Mvar), grid fault ride-through protection, and intelligent power flow control, meeting SIL 3/PLe safety standards.
The 3BHE046081E16 unit, a core component of the PCS6000 grid circuit breaker and part of the GBU (Gate Board Unit) series, is responsible for grid-side circuit breaker control, fault response, system protection, and synchronization coordination. Models include 3BHE031197R0001 and 3BHE055094R0002, and are compatible with drive systems such as ACS6000 and DCS5000.
3BHE046081E16 Technical Parameters and Features
Electrical Performance: Rated voltage 72.5kV, rated current 3150A, insulation level 170kV, breaking capacity 25kA, control voltage 220V AC/24V DC. Supports 50/60Hz frequency, response time <1μs, integrated overcurrent/overvoltage/undervoltage protection, arc extinguishing, and redundant protection circuits.
Interface and Communication: Connects to the main controller (such as the AC800PEC) via optical fiber, supports MODBUS or customized protocols, and is compatible with PMI/PEC/HMI module data exchange.
Physical Design: Industrial standard control cabinet structure, IP54 protection rating, supports cabinet installation, cooling methods include natural ventilation or forced air cooling, and weighs approximately 600kg.
PCS6000 Power Conversion System
The 3BHE046081E16 is a modular, high-efficiency variable-frequency power system designed for applications such as grid connection to incompatible grids, industrial load balancing, and dynamic voltage restoration.
Core Features:
Power Range: 4-120 MVA (4-12 MVA per module), with support for parallel expansion of multiple modules.
Technical Advantages: High efficiency even at partial loads, low maintenance costs, and a compact design (e.g., shore-based frequency conversion, railway grid connection, and ship-to-shore connection).
Applications: Wind power grid connection, industrial motor drives, dynamic reactive power compensation (STATCOM), and specialized industrial process control.
Service Support: Turnkey solutions are provided, with a global service network supporting remote diagnostics and local maintenance.
2. 3BHE046081E16 Grid Breaker Unit (ABB)
Product Positioning: A core component of ABB industrial drive systems (such as the ACS 6000 and DCS series), this unit is a grid-side circuit breaker unit used for the protection and control of medium- and high-voltage power grids or high-power variable-frequency drive systems.
Core Functions:
Electrical Protection: Provides precise switching control of power semiconductors (IGBT/GTO), providing protection against overcurrent, short-circuit, and other faults.
System Synchronization: Responsible for circuit breaker operations, grid-side voltage synchronization, and communication coordination during grid connection and disconnection.
Industrial Applications: Widely used in high-power motor control scenarios in metallurgy, power plants, chemicals, cement, and other industries, ensuring high-voltage startup and shutdown safety and fault isolation.
Technical Parameters (using a typical model as an example):
Rated Voltage: 24kV (some models up to 72.5kV).
Rated Current: 12,000A (some models up to 3150A).
Insulation and interrupting capacity: 170kV insulation level, high-reliability redundant circuit design.
Relationship and application synergy
System integration: In the PCS6000 system, the 3BHE046081E16 often serves as a core control cabinet unit (such as model 3BHE031197R0001), responsible for circuit breaker control, status feedback, interface communication, and system protection. For example:
In wind power grid-connected scenarios, the 3BHE046081E16 ensures stable connection and fault isolation between the PCS6000 and the grid.
In industrial drive systems, the 3BHE046081E16 works with the PCS6000 to achieve precise control and safe starting and stopping of high-voltage motors.
Typical application scenarios:
In the wind power sector: The 3BHE046081E16 implements grid-side circuit breaking and synchronization control in PCS6000 wind turbine converters.
Industrial Automation: Ensures safe operation and fault response of high-voltage equipment in high-power drive applications such as steel rolling and mining.
Grid Protection: As part of the grid-side protection equipment, it supports power-off protection, system interlocking, and automated control logic.
Application Scenarios and System Integration
Industrial Drives: Controls the start and stop of high-power motors in applications such as metallurgy, mining, and cement production, achieving safety isolation and fault protection.
Renewable Energy: Ensures stable operation of IGCT modules in wind power converters, adapting to offshore wind power projects (such as 14MW wind turbines), supporting grid compliance and voltage stability.
Grid Protection: As a grid-side protection device, it provides power-off protection, fault isolation, and system interlocking, and is used in rail transit, energy storage systems, and dynamic voltage restoration scenarios.
System Collaboration: Works in conjunction with rectifiers and inverters to execute power-on sequencing, main circuit isolation, and safety lockout logic, ensuring stable operation in high-voltage environments.
Installation and Maintenance Key Points
Installation Requirements: Ensure proper crimping pressure and heat sink contact on the IGCT module. Properly connect the 24V DC power supply and fiber optic interface to prevent electrostatic damage. The cabinet must meet IP54 protection standards and support cabinet installation.
Maintenance Guide: Regularly check electrical parameters (current/voltage monitoring), arc extinguishing chamber status, and protection functions. Remote parameter configuration (such as drive thresholds and protection parameters) is supported. Troubleshooting should combine system logs with communication data from the main controller to quickly locate abnormalities such as overcurrent/overvoltage.
Certifications and Standards
Compliant with IEC 61508 and ISO 13849 safety standards, certified by the Beijing General Certification Center (CGC) and DNV-GL, and meeting GB/T 25387-2010 and GL-IV-2:2012 specifications. Global application cases include 1,000 MW offshore wind power projects.
Summary
The PCS6000 and 3BHE046081E16 , provided by Hitachi Energy and ABB, respectively, complement each other in industrial power conversion and protection systems. The PCS6000 provides efficient power conversion, while the 3BHE046081E16 ensures electrical safety and reliable operation. Together, they serve critical applications such as high-power motor control, grid connection, and industrial process automation.
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