ABB 5SHX1960L0006 3BHB016120R0002 3BHE019719R0101 GVC736BE101 High Voltage Inverter Module

ABB 5SHX1960L0006 3BHB016120R0002 3BHE019719R0101 GVC736BE101 High Voltage Inverter Module

Product Overview

The ABB high-voltage inverter module under focus this time includes 5SHX1960L0006 (power unit core component), 3BHB016120R0002 (control unit), 3BHE019719R0101 (power drive board), and GVC736BE101 (signal conditioning module), which are the core components of ABB ACS800/ACS6000 series high-voltage inverters. This module combination is positioned at the core of “high voltage adaptation+efficient frequency conversion+precise control”, designed specifically for 6kV/10kV high voltage motor drive scenarios. It integrates multiple functions such as power conversion, signal processing, logic control, and fault protection, and can directly drive high-power high voltage loads such as fans, pumps, compressors, etc., achieving smooth adjustment of motor speed and energy consumption optimization. It is widely used in industries such as power, metallurgy, mining, and chemical industry that require strict reliability and energy efficiency of high voltage transmission systems.

This module combines ABB’s core technologies in high-voltage power electronics, frequency conversion control algorithms, and industrial reliability design. It adopts a modular power unit topology and digital control architecture, and has strong high-voltage tolerance, high frequency conversion efficiency, excellent output waveform quality, and outstanding anti-interference performance. Among them, 5SHX1960L0006 serves as the core power device to provide stable high-voltage conversion support, 3BHB016120R0002 realizes overall control logic scheduling, 3BHE019719R0101 ensures precise power signal driving, and GVC736BE101 completes multi-dimensional signal conditioning and transmission. The four work together to build an efficient and reliable high-voltage variable frequency drive system, which is a key equipment for achieving energy conservation, consumption reduction, and precise control in high-voltage industrial scenarios.

Core functions and technical features

1. Core power conversion and control functions

-High voltage adaptation and efficient power conversion: The core power component 5SHX1960L0006 adopts IGBT (Insulated Gate Bipolar Transistor) power devices, with a rated voltage level of 3.3kV and a rated current of 1200A. It supports 6kV/10kV high voltage input and converts fixed high voltage AC power into adjustable voltage and frequency regulated three-phase AC power through multiple PWM (Pulse Width Modulation) technology. The frequency conversion efficiency is ≥ 98.5% and the power factor is ≥ 0.95 (under rated load), effectively reducing the starting impact and operating energy consumption of high voltage motors.

-Accurate speed regulation and load adaptation: The 3BHB016120R0002 control unit is equipped with advanced vector control algorithms and PID regulation modules, supporting three modes of speed closed-loop control, torque closed-loop control, and power closed-loop control. The speed control accuracy reaches ± 0.1%, and the motor speed can be smoothly adjusted according to the flow and pressure requirements of loads such as fans and pumps, achieving “on-demand energy supply” and saving 20% -50% energy compared to traditional throttling regulation methods.

-Multi dimensional signal processing and driving collaboration: The GVC736BE101 signal conditioning module integrates 12 high-precision analog acquisition channels and 8 digital input/output interfaces, using a 16 bit A/D conversion chip with a sampling rate of 500Hz, which can accurately collect operating parameters such as motor temperature, bearing vibration, output current and voltage; The 3BHE019719R0101 power drive board converts the logic instructions of the control unit into IGBT drive signals, with a drive delay of ≤ 1 μ s, ensuring synchronous response between power conversion and control instructions.

-Comprehensive fault protection and fault tolerance mechanism: The module combination is equipped with a complete hierarchical protection function, including overcurrent protection (response time ≤ 5 μ s), overvoltage protection, undervoltage protection, overtemperature protection, IGBT fault protection, motor stalling protection, and ground fault protection; Support hot swapping function for power units, which can automatically shut down in case of a single unit failure. The remaining units are maintained at reduced capacity through redundant control to ensure uninterrupted production process.

2. Additional practical features

-Rich communication and monitoring capabilities: The 3BHB016120R0002 control unit supports mainstream industrial communication protocols such as PROFINET, Modbus TCP/RTU, IEC 61850, etc. It is equipped with 2 Gigabit Ethernet interfaces and 1 RS485 interface, which can seamlessly connect to DCS systems, upper monitoring platforms, and intelligent operation and maintenance systems, realizing real-time uploading of frequency converter operating parameters, remote setting and fault alarm push; Simultaneously supporting local LCD panel operation, convenient for on-site debugging and status viewing.

-Flexible topology adaptation and expansion: Adopting a modular power unit parallel topology, the number of power units can be flexibly configured according to the motor power requirements (supporting 6-18 units in parallel), suitable for high-voltage motors of different power levels from 500kW to 10MW; Support collaborative operation with ABB SVG (Static Var Generator), soft starters, and other devices to enhance the stability and power quality of high-voltage distribution systems.

-Energy optimization and grid friendliness: It has the ability to operate in four quadrants (requiring the configuration of an energy feedback unit), and can feedback the regenerated electrical energy generated during the motor braking process to the high-voltage grid, further reducing energy consumption; The output side adopts multiple PWM technology, with a harmonic distortion rate (THD) of ≤ 5%, which can meet the GB/T 14549-1993 power grid harmonic standard without the need for additional filtering devices, reducing interference to the power grid.

-Strong environmental adaptability and high reliability: Each module uses industrial grade high weather resistant components. The 5SHX1960L0006 power component has passed the 10kV insulation withstand voltage test, and the 3BHB016120R0002 control unit has passed the IEC 61000-6-4 electromagnetic compatibility test; The overall working temperature range is -10 ℃~+55 ℃, with a protection level of IP21 (power unit)/IP40 (control unit), which can adapt to complex environments such as high temperature, high dust, and strong electromagnetic radiation in industrial sites.

Key technical parameters

Core power device (5SHX1960L0006)

IGBT type: 3.3kV/1200A; Packaging form: modular; Switching frequency: 200Hz-1kHz (adjustable)

High voltage and high current adaptation, supporting variable frequency requirements for different loads

Input/output parameters

Input voltage: 6kV/10kV ± 10% (three-phase AC); Output voltage: 0-6kV/0-10kV (adjustable); Output frequency: 0-60Hz (adjustable)

Adapt to mainstream high-voltage distribution systems to meet the requirements of motor speed regulation

Control unit (3BHB016120R0002)

Processor: Dual core industrial grade CPU with a clock speed of ≥ 1GHz; Control algorithms: vector control, direct torque control (DTC); Control accuracy: speed ± 0.1%, torque ± 1%

High precision control ensures the stability of motor operation

Power drive board (3BHE019719R0101)

Drive signal delay: ≤ 1 μ s; Insulation voltage: 5kV AC/1min; Drive current: 0-5A (adjustable)

Quickly respond to control commands to ensure precise power conversion

Signal conditioning module (GVC736BE101)

AI channel: 12 channels (4-20mA DC), 16 bit accuracy; DI/DO: 8 routes/6 routes; Sampling rate: 500Hz

Accurately collect operational parameters to provide a basis for control decisions

Protect performance

Overcurrent protection: instantaneous action at 1.5 times rated current; Overvoltage protection: operates at 1.15 times the rated voltage; Over temperature protection: IGBT junction temperature ≥ 150 ℃ action

Comprehensive guarantee of module and motor safety

communication interface

2-channel Gigabit Ethernet (PROFINET/IEC 61850); 1 RS485 (Modbus RTU) channel; 1 CANopen channel

Support multi system interconnection, achieve remote monitoring and operation and maintenance

environmental parameters

Working temperature: -10 ℃~+55 ℃; Humidity: 5%~95% (no condensation); Protection level: IP21 (power unit)/IP40 (control unit)

Adapt to complex industrial site environments

physical parameters

Power unit size: 600mm × 400mm × 200mm; control unit size: 300mm × 200mm × 150mm; installation method: cabinet installation

Standardized dimensions for easy system integration

Typical application scenarios

This high-voltage inverter module combination is widely used in high-voltage industrial drive scenarios due to its high-voltage adaptability, precise control performance, and high reliability. Typical scenarios include:

1. Fan and water pump control in the power industry: used for high-voltage variable frequency drive of induced draft fans, supply fans, primary fans, and feed pumps in thermal power plants. By adjusting the motor speed to match the boiler load requirements, it saves 30% -40% energy compared to traditional baffle throttling adjustment methods, while reducing mechanical wear of fan and water pumps and extending equipment service life.

2. Control of rolling mills and fans in the metallurgical industry: In the main rolling mill and coiling machine drive of the hot rolling production line in the steel plant, high-precision speed and torque control of the motor is achieved through vector control algorithms to ensure the accuracy of steel strip rolling; In the control of blast furnace blower and converter dust removal fan, adapt to severe load fluctuations to ensure stable air pressure and dust removal effect.

3. Equipment drive for mining and coal industry: High voltage variable frequency drive used for coal mine main ventilation fans, main drainage pumps, and belt conveyors, with underground explosion-proof adaptability (explosion-proof shell needs to be configured), achieving unmanned operation through remote monitoring, and using soft start function to avoid the impact on the power grid when the motor starts, ensuring the safety of mine power supply.

4. Compressor control in the chemical and petrochemical industries: In the high-pressure drive of air compressors and feed gas compressors in chemical plants, torque closed-loop control is used to achieve smooth operation of the compressors and avoid equipment failures caused by sudden load changes; In the control of crude oil transportation pumps, the speed is adjusted according to the demand for transportation volume to reduce pipeline energy consumption and wear.

5. Large scale equipment for municipal and environmental protection industries: used for large aeration fans and sludge dewatering machines in urban sewage treatment plants, as well as high-pressure drives for induced draft fans and primary fans in waste incineration power generation projects. By accurately adjusting the speed, process parameters are optimized to improve sewage treatment efficiency and waste incineration efficiency, and reduce operating costs.

6. Kiln equipment in the cement and building materials industry: used for the main drive of the rotary kiln and the high-voltage variable frequency drive of the grate cooler fan in the cement production line, adapting to the periodic changes in load during the cement production process, ensuring stable kiln speed and clinker cooling effect, while achieving energy conservation, consumption reduction, and production efficiency improvement.

Installation and maintenance precautions

1. Installation specifications

-The module combination needs to be installed in a dedicated high-voltage inverter cabinet, which should be arranged in a well ventilated control room without severe vibration (vibration acceleration ≤ 2g), corrosive gases, and conductive dust, away from high-voltage busbars and strong electromagnetic interference sources; The distance between the cabinet and the wall should be ≥ 1.5m, and the distance between cabinets should be ≥ 1m to ensure sufficient space for maintenance and heat dissipation.

-High voltage wiring must strictly follow the “power-off verification” process. The input side should be connected to the switchgear using high-voltage cables, and the cable cross-section should match the rated current of the module (300mm ² copper core cables are recommended for 1200A current); The connection between the output side and the motor must ensure correct phase sequence to avoid motor reversal; All high-voltage wiring terminals must be tightened with a torque wrench according to the specified torque to prevent poor contact and heat generation.

-The control circuit and high-voltage circuit need to be strictly separated and wired. The control cable adopts twisted pair shielded wire, and the shielding layer is grounded at one end (grounding resistance ≤ 4 Ω); The analog and digital cables of the GVC736BE101 signal conditioning module are laid separately with a spacing of ≥ 200mm to avoid interference from high-voltage circuits on the signal.

-The cabinet should be equipped with a forced ventilation or water-cooled cooling system to ensure that the temperature inside the cabinet is controlled within the range of -10 ℃ to+55 ℃; The grounding of the power unit and control unit should be separately connected to independent grounding terminals, and then aggregated to the system grounding grid to avoid equipment failures caused by grounding circulation.

2. Maintenance points

-During daily inspections, check the operating parameters of the module (IGBT junction temperature, output current and voltage, motor speed, power factor) through the upper monitoring system or local LCD panel to confirm that there are no abnormal alarms; Focus on checking the operating status of the power unit cooling fan, the temperature of the high-voltage wiring terminals (≤ 60 ℃), and whether the insulation parts are damaged.

-Clean and maintain once a quarter, use compressed air (pressure ≤ 0.2MPa) to clean the power unit heat sink, cabinet filter, and control unit dust after power outage, and wipe the interface and wiring terminals of GVC736BE101 module with a dry soft cloth; Check the wear of the cooling fan bearings, and replace them promptly if any abnormal noise occurs.

-Conduct insulation testing and parameter calibration every six months, and use a 2500V megohmmeter to measure the insulation resistance of the power unit input and output to ground (≥ 100M Ω is qualified); Calibrate the signal acquisition accuracy of GVC736BE101 through dedicated debugging software, and verify the consistency between the protection setting of 3BHB016120R0002 control unit and the process requirements.

-Regularly check the IGBT drive signal of the power drive board (3BHE019719R0101), measure the drive pulse waveform through an oscilloscope, and ensure that the waveform is distortion free; Check the voltage balance of the 5SHX1960L0006 power module to avoid overvoltage operation of individual modules.

-When a module malfunctions, immediately disconnect the high-voltage input switch and locate the faulty module through the fault code (such as IGBT fault corresponding to code F023); When replacing a module, it is necessary to ensure that the new module model is exactly the same as the original module. After replacement, insulation testing and no-load trial operation should be carried out to confirm that there are no abnormalities before operating with load.