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　　3BHB056372R0003 Other Names:

　　Central Processing Unit 3BHB056372R0003

　　3BHB056372R0003 Excitation Control Unit

　　Input/Output Communication Unit 3BHB056372R0003

　　PCS6000 Medium Voltage Full Power Converter: Designed for large wind turbines with a power range up to 12 MW, it utilizes a three-level, four-quadrant VSI-NPC topology and supports nacelle or tower installation. Its modular design (e.g., T-type/horizontal layout) allows for flexible adaptation to different power requirements while reducing cable loss and installation costs. The system features high efficiency (approximately 98% efficiency at rated point) and low losses, and utilizes IGCT technology to reduce component count and improve reliability.

　　Key Features:

　　Grid Adaptability: Supports 50/60Hz grid frequencies and features fault ride-through (such as low-voltage/high-voltage ride-through) and a dynamic braking chopper to ensure wind turbines remain connected during grid disturbances.

　　Control and Communication: Integrated with the AC800PEC controller, it supports bus protocols such as Profibus DP, Profinet IO, and Modbus TCP, enabling remote monitoring and VPN access via Ethernet.

　　Environmental Adaptability: IP54 protection rating, operating temperature range -10°C to 45°C, and a closed-loop water-cooling/air-cooling dual-mode cooling system for adaptability to harsh environments.

　　High-Performance Processing: Utilizing a dual-core processor architecture, it supports multi-stage task processing from 25ns to 1ms, with data throughput as low as 100μs, meeting the requirements for synergistic coordination between high-speed control loops (e.g., 100μs cycle) and low-speed process control. An integrated FPGA enables nanosecond-level task processing, meeting the rapid response requirements of power electronics.

　　Modular Design: Based on the IEC 61131-3 standard, it supports modular I/O expansion (such as the ANYIO bus and Profibus), is compatible with ABB S800 I/O devices, and adapts to the automation needs of process industries, power generation and distribution, and transportation and traction.

　　High Reliability: A modular design, long-life components (such as IGCT modules), and wide temperature adaptability (IP54 protection) support operation in harsh environments.

　　Grid Compliance: Built-in dynamic braking, high and low voltage ride-through, and harmonic suppression functions comply with global grid regulations.

　　Scalability: The power range can be expanded up to 120MVA (static inverter), and customized configurations are supported.

　　High-performance architecture: Combining CPU floating-point computing (750MHz RISC processor + 64-bit FPU) with FPGA high-speed processing, it supports three-level task allocation:

　　Ultra-fast tasks: as low as 25 nanoseconds (FPGA-driven, such as nanosecond switch control)

　　Fast tasks: as low as 100 microseconds (Matlab/Simulink real-time control)

　　Slow tasks: as low as 1 millisecond (conventional control logic)

　　Communication capabilities: Integrates protocols such as MMS, Modbus TCP/RTU, PROFIBUS, IEC61850, and ABB fiber optic links, supporting seamless integration with System 800xA and compatibility with CEX bus expansion modules (such as the TK850V007 cable).

　　I/O and expandability: The fast I/O system boasts data throughput of ≤100μs and supports multiple module expansion (such as the DI810 digital input and DSAO120A analog output), making it suitable for scenarios such as industrial automation and power electronics.

　　Functional Architecture Analysis

　　Control Logic: Algorithm development is achieved through the Control Builder M programming environment (supporting MATLAB/Simulink). This system combines vector control and sensorless algorithms to optimize power conversion efficiency (>98%) and supports advanced features such as grid fault ride-through, dynamic braking, and high and low voltage ride-through.

　　Protection Mechanism: Built-in overvoltage/overcurrent protection, short-circuit protection, and grid fault isolation modules (such as the GBU72 circuit breaker unit), along with redundant features (such as dual power supplies and redundant communication links), ensure high system availability.

　　Expandability: Supports CEX bus expansion, pre-charging units, and cooling system (air-cooled/water-cooled closed-loop) integration, making it suitable for high-power scenarios such as wind turbines (3-15MW), static inverters (10-120MVA), and industrial drives.

　　AC 800PEC Controller 3BHB056372R0003

　　Core Function: Serving as the "brain" of the PCS6000, it precisely coordinates the generator side (pulse width modulation control) and the grid side (optimized pulse mode control), achieving active/reactive power regulation, speed control, and fault protection. Its high-speed RISC processor (750MHz, 64-bit FPU) delivers millisecond-level response, meeting the dynamic control requirements of wind power generation.

　　Technical Highlights:

　　Redundant Design: Dual-channel configuration allows independent operation of the main and backup control boards, with automatic failover in the event of a fault, ensuring system continuity.

　　Expandability: Supports a variety of I/O module expansions, is OPC UA compatible, and can be integrated into DCS/PLC systems, adapting to various scenarios such as thermal power, hydropower, and smart grids.

　　Algorithm Advantage: Utilizes a sensorless control algorithm, combining PID regulation with predictive maintenance functions, to optimize voltage stability and load fluctuation management.

　　Model Association: The 3BHB056372R0003 belongs to the AC800PEC series and works with modules such as the PCD237A101. It supports excitation control, rotor positioning, and remote debugging, and is widely used in synchronous generator and speed regulator coordination and reactive power compensation scenarios.

　　High-Speed Control: Cycle times as low as 100μs support fast power control, grid synchronization, and fault protection.

　　Multi-Level Processing: A dual-core processor + FPGA architecture enables hierarchical processing of ultra-fast tasks (nanosecond level) and routine tasks.

　　Communication Capabilities: Fiber optic links, AnyIO interface, integration with the ABB ControlIT environment, and support for IEC 61131-3 programming.

　　Protection Mechanisms: Overload, short-circuit, and overvoltage protection, grid fault ride-through, and remote monitoring and diagnostics.

　　Technical Parameters:

　　Processor: 64-bit IEEE floating-point unit, supports MATLAB/Simulink model import.

　　I/O Expansion: Compatible with S800 low-level I/O modules, supporting high-speed signal exchange.

　　Cooling System: Closed-loop water/air cooling ensures thermal management at high power density.

　　Application Scenarios and Value

　　Wind Power: In large offshore/onshore wind turbines, the PCS6000 significantly reduces the cost of electricity (LCoE) by reducing drivetrain losses and improving power generation efficiency. Its fault ride-through capability ensures grid stability and complies with international standards such as DNV-GL and CE.

　　Cross-Industry Applications: The AC 800PEC controller is also suitable for applications in thermal power, hydropower, metallurgy, and petrochemical industries, such as boiler control, turbine speed regulation, and arc furnace power factor regulation. It improves overall automation by unifying high-speed control and low-speed process tasks.

　　Renewable Energy: As the core controller for wind turbine full-power converters, it optimizes energy production efficiency and meets grid code compliance (e.g., fault ride-through and reactive power regulation).

　　Industrial Applications: In steel, mining, and port cranes, it drives large motors (such as synchronous motors and centrifugal compressors) to achieve precise speed/torque control and optimize energy efficiency.

　　Grid Stability: Dynamic voltage stabilization, harmonic filtering, and reactive power compensation are achieved through static synchronous compensators (STATCOMs), improving the quality of utility grids.

　　Technical Specifications Summary

　　PCS6000: Rated voltage 3.3kV/4.16kV, generator-side frequency adjustable from 0-120Hz, du/dt<1.5kV/μs, cooling water inlet temperature ≤45°C.

　　AC800PEC: 750MHz processor, supports 36 fiber optic links, includes communication interfaces such as Profibus and EtherCat, and has a protection level that meets industrial environment requirements.

　　Wind Power Case Study: The Global Tech I wind farm in Germany uses the PCS6000 to achieve efficient operation of 12MW wind turbines and reduce the cost of electricity (LCoE).

　　Industrial Applications: Used in STATCOMs for dynamic voltage stabilization and reactive power compensation; in industrial drives, it supports precise control of large equipment (such as mine hoists and rolling mills). Maintenance and Operational Specifications

　　Installation Environment: Avoid strong electrical interference, electrostatic damage, and direct sunlight. The ambient temperature range is wide (typically IP54 protection). The cooling system requires regular inspection (e.g., circulating a deionized water/ethylene glycol mixture).

　　Maintenance Procedures: Support remote monitoring tools (such as PECView) combined with fault diagnosis software for real-time status monitoring and fault location. Operations must be performed by qualified personnel and follow ESD protection regulations to avoid arbitrary power outages or unauthorized software modifications.

　　Training Support: ABB offers operation and maintenance training courses (such as G820/G830) covering hardware replacement, troubleshooting, and software configuration to ensure long-term stable system operation.

　　Cooling System: The closed-loop water cooling system requires regular inspection of the deionized water/ethylene glycol mixture to prevent corrosion or blockage.

　　Grid Compatibility: Configure protection parameters according to local grid specifications to ensure fault ride-through capability.

　　Software Tools: Use ABB Control Builder M for IEC 61131-3 programming, combined with MATLAB/Simulink for advanced control algorithms. Firmware and Extended Functions

　　Firmware Features: Supports sensorless algorithms, predictive maintenance (such as PERMS resistance measurement), open circuit protection (OPC standalone PLC), and compatibility with remote monitoring tools (such as the ABB Service Tool).

　　Expansion Modules: Can integrate Anybus modules (such as CANopen and EtherCAT) and safety modules (SIL3 certified), supporting redundant architectures and emergency stop response (10ms level).

　　The AC 800PEC controller (3BHB056372R0003), the "brain" of the ABB PCS6000 system, offers high-performance, low-maintenance solutions for wind power generation and other industrial scenarios through its high-reliability design, efficient energy conversion, and intelligent control, meeting the needs of global energy transition and sustainable development.

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