ABB PCS6000 PRODUCT FAMLIYThe medium-voltage full-power converters of the ABB PCS6000 PRODUCT FAMILY are designed specifically for large turbines. Their features include a small number of parts, high availability, and minimized losses. The higher voltage level of the MV converters means lower current in the electrical drive system, and the converters are also easier to integrate into turbines. These converters can be designed for nacelle or tower base installation, and their modular design makes it easy to customize them to meet customer requirements. In addition, they have the ability to continue operation in case of faults and comply with grid regulations.
It is one of the core product lines of ABB medium-voltage frequency converters.
Designed specifically for industrial applications, it realizes precise speed control of AC motors.
Core goals: Improve energy efficiency, optimize processes, and enhance equipment reliability.
Technical foundation: Based on Modular Multilevel Converter (MMC) technology (for specific voltage levels).
Positioning: A solution with high power density and high reliability.ParametersVoltage levels: 3.3 kV, 4.16 kV, 6.6 kV, 6.9 kV, 10 kV, 11 kV.Power range: Usually covers approximately 1 MW to 28 MW and above (depending on voltage and model).Output frequency: 0 to 120 Hz (standard), can be customized to higher.Efficiency: Usually > 98% (including transformer).Input power factor: Close to 1 (no additional power factor compensation device required).Overload capacity: Usually 110% continuous operation, 120% for 60 seconds, 150% for 2 seconds.Control accuracy: Speed control accuracy is usually better than 0.1% (open loop), 0.01% (closed loop).Protection level: Cabinets are usually IP21, IP31, IP42 or higher (depending on configuration and application requirements).Product FeaturesExcellent energy efficiency: Four-quadrant operation capability (regenerative energy feedback to the grid), high system efficiency. < 3-5% @ full load), high input power factor (~1), compliant with strict grid specifications.THiDPerfect grid performance: Extremely low harmonic distortion (Excellent motor performance: High-quality sinusoidal output current/voltage, low dv/dt, protects motor insulation, reduces the risk of bearing current, supports standard asynchronous motors and permanent magnet motors.High reliability:Modular design (with optional redundancy for key components).Robust power semiconductor design.Advanced cooling system (air-cooled or water-cooled).Built-in diagnostic and monitoring functions.Flexibility and scalability:Modular architecture facilitates maintenance and upgrades.Multiple cabinet sizes and configurations available.Easy integration into automation systems (supports multiple communication protocols).User-friendly:Graphical control panel/human-machine interface (HMI).Intuitive debugging and parameter setting tools.Comprehensive diagnostic and event recording functions.Low maintenance requirements: Long-life design, support for predictive maintenance.Structure and CompositionInput transformer (optional but common): Provides electrical isolation, voltage matching, reduces common-mode voltage, and reduces harmonics.Rectifier/input unit:Based on power semiconductors such as IGCT/IGBT.Realizes grid-side Active Front End (AFE), ensuring four-quadrant operation and low harmonics.DC bus: Energy storage and energy transmission link.Inverter/output unit:Also based on IGCT/IGBT etc.Converts DC power into three-phase AC power with adjustable frequency and voltage to drive the motor.Adopts multi-level topology (such as NPC, CHB, MMC) to obtain high-quality output waveforms.Control unit:Core processor (DSP/FPGA).Implements motor control algorithms (V/f, vector control, DTC optional).Handles communication, I/O, and protection logic.Operation monitoring system.Cooling system: Forced air cooling (fan) or water cooling system to ensure that power devices work at safe temperatures.Switchgear and protection devices: Include input/output circuit breakers, contactors, protection relays, fuses, etc.): Local operation panel for monitoring, parameter setting, and fault checking.HMIHuman-machine interface (, etc.).CANopen, Ethernet/IP, Modbus TCP, Profibus DP terminals; supports fieldbuses (such as I/OInterface and communication: Digital/analog Sensor interface: Used to connect motor speed/position feedback (encoder/resolver).Application FieldsMining: Large fans, water pumps, mills, belt conveyors, hoists.Metallurgy: Main drives of rolling mills, fans, water pumps, compressors, roller tables.Oil and gas: Pipeline compressors, water injection pumps, main fans/compressors on offshore platforms.Water and wastewater treatment: Large water intake pumps, water supply pumps, sewage lifting pumps, aeration fans.Electric power: Boiler feed pumps, induced draft fans, forced draft fans, circulating water pumps, condensate pumps.Chemical and petrochemical: Large compressors, pumps, mixers, extruders.Cement: Raw material mills, cement mills, fans, crushers.Pulp and paper: Pulpers, paper machines, fans, compressors.Marine: Main propellers, thrusters, large pumps/fans (requires classification society certification).Test bench: High-power motor/engine test platforms.Installation and MaintenanceInstallation:Environmental requirements: Clean, dry, well-ventilated, free of corrosive gases, ambient temperature/humidity in line with specifications, sufficient space (operation and maintenance channels).Foundation: Solid and flat concrete foundation.Electrical connection: Strictly follow the drawings for high-voltage input, motor output, auxiliary power, and grounding (extremely important) connections. Professional high-voltage electricians are required for operation.Cooling system connection: Ensure unobstructed air ducts or correct water circuit connection (water-cooled type), with flow/pressure/water quality up to standard.Control system integration: Connect I/O signal lines and communication buses.Commissioning:Inspection before system power-on (insulation, wiring, mechanics).Auxiliary power-on test.Control software parameter configuration (motor data, application macros, protection settings, etc.).No-load test (output voltage, waveform, phase sequence).No-load test with motor (rotation direction, basic control).Load test and optimization (speed loop, current loop tuning).Maintenance:Regular inspection:Cleaning: Regularly remove dust inside and outside the cabinet (after power off!), ensure radiators/filters are clean, and fans operate normally (air-cooled).Electrical connection inspection: Tighten main circuit and control circuit terminals (according to standard torque, usually requiring power outage).Cooling system inspection: Fan status (air-cooled), water pump, pipeline, filter, and coolant status (water-cooled).Status of key components: Capacitor appearance (no bulging, leakage), resistor status, etc.Preventive maintenance:Replace cooling fans according to operating time and environmental conditions.Replace coolant and filters in water cooling systems (water-cooled type).Inspect, clean/replace dust filters.Perform functional tests (such as protection function verification).Condition monitoring:Use built-in diagnostic tools to monitor operating parameters (temperature, current, voltage, fault records).Analyze operating data to predict potential faults.Fault handling:Refer to the fault codes and information displayed on the HMI.Consult the manual for fault diagnosis and elimination.Replace faulty modules (benefiting from modular design).Spare parts management: Reserve key vulnerable parts and modules.
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