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3BHE046836R0102 Other names:
Central processing unit ABB 3BHE046836R0102
ABB 3BHE046836R0102 PLC processing board
Functional module ABB 3BHE046836R0102
ABB GFD563A102 | 3BHE046836R0102 | GF D563 A102, AC 800PEC controllers are suitable for industries such as industrial automation and machinery, utilities and energy, process control and monitoring. The AC 800PEC toolbox is required to access the controller hardware. Using Simulink external mode can achieve user-friendly monitoring. If an AC 800PEC controller is required, it can be programmed using ABB’s Control Builder M programming tool (compliant with IEC 61131-3), as well as MATLAB, Simulink, and Simulink Coder. The AC 800PEC toolbox is required to access the controller hardware. Using Simulink external mode can achieve user-friendly monitoring. ABB GFD563A102 | 3BHE046836R0102 | GF D563 A102 AC 800PEC controller is a powerful tool for controlling high-speed and low-speed processes in various industries. It can be programmed using ABB’s Control Builder M programming tool (compliant with IEC 61131-3), as well as MATLAB, Simulink, and Simulink Coder. You need to use the AC 800PEC toolbox to access the controller hardware and can use Simulink external mode for user-friendly monitoring. ABB GF D563 | 3BHE046836R0101 | GFD563A101 | AC 800PEC. ABB AC 800PEC is a controller that combines high-speed control requirements for processes such as power electronics applications with low-speed process control tasks typically performed by separate PLC units. It uses ABB’s Control Builder M programming tool (compliant with IEC 61131-3), as well as MATLAB, Simulink, and Simulink Coder for configuration and programming. The AC 800PEC is connected to ABB’s I/O system through the optical S800 ModuleBus and to ABB’s communication module through the Communication Expansion Bus (CEX). It also supports third-party Anybus-S fieldbus modules.
To use the AC 800PEC controller in Compact Control Builder 5.1, you can refer to the manual or documentation related to the configuration of the AC 800PEC controller.
The AC 800PEC GFD563 controller can be used in industries such as industrial controllers and PLCs, control systems, digital signal processing, embedded systems, process control and monitoring, real-time systems, industrial automation and machinery, utilities and energy.
Multi channel control: This module typically has multiple control channels and can be used to simultaneously monitor and controlmultiple power generators.
Communication interface: The PCD231B101 module tpically supports communication interfaces for data exchange and communicationwith other devices, control systems, or monitoring systems.
Curent and voltage monitoring: Modules typically have current and voltage monitoring functions to monitor the electrical parameters ofthe generator in real-time.
Current and voltage regulation: This control module can usually adjust the excitation current and voltage of the generator to meet the needs of the power system.
Protection and safety: Excitation control modules tpically have protection functions to monitor and protect the generator from overcurrent, overvoltage, or other faults.
Alarm and diagnosis: Modules are usually able to monitor abnormal situations and generate alarm information to assist operators or control systems in taking appropriate measures.
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ABB GFD563A102 | 3BHE046836R0102 | GF D563 A102, AC 800PEC controllers are suitable for industries such as industrial automation and machinery, utilities and energy, process control and monitoring. The AC 800PEC toolbox is required to access the controller hardware. Using Simulink external mode can achieve user-friendly monitoring. If an AC 800PEC controller is required, it can be programmed using ABB’s Control Builder M programming tool (compliant with IEC 61131-3), as well as MATLAB, Simulink, and Simulink Coder.
admin –
It is worth noting that the Application Knowledge Base (AKS) will no longer be available after July 31, 2021. ABB is enhancing its customer and partner experience and migrating data from AKS to a new portal. ABB AC 800PEC is a controller that combines high-speed control requirements for processes such as power electronics applications with low-speed process control tasks typically performed by separate PLC units. It can be programmed using ABB’s Control Builder M programming tool (compliant with IEC 61131-3), as well as MATLAB, Simulink, and Simulink Coder. It is connected to ABB’s I/O system through the optical S800 ModuleBus and to ABB’s communication module through the Communication Expansion Bus (CEX). It also supports third-party Anybus-S fieldbus modules. The controller can be programmed using Simulink and Simulink Coder. The AC 800PEC toolbox is required to access the controller hardware. Using Simulink external mode can achieve user-friendly monitoring. It can be used in various industries such as industrial controllers and PLCs, control systems, digital signal processing, embedded systems, process control and monitoring, real-time systems, industrial automation and machinery, utilities, and energy.
admin –
The 3BHE046836R0102 excitation central processing unit module supports a variety of analog and digital input and output combinations, and can process multiple signals simultaneously. The specific input and output configuration may include digital input, analog input, digital output, and high-speed digital output, etc., to meet complex control requirements. At the same time, through additional expansion modules, the configuration of this module can be further expanded to adapt to more complex application requirements in the fields of industrial automation and robotics. The expansion modules can be installed locally or remotely, providing greater flexibility and convenience.
admin –
The GFD563A102 3BHE046836R0102 excitation central processing unit module supports a variety of analog and digital input and output combinations, and can process multiple signals simultaneously. The specific input and output configuration may include digital input, analog input, digital output, and high-speed digital output, etc., to meet complex control requirements. At the same time, through additional expansion modules, the configuration of this module can be further expanded to adapt to more complex application requirements in the fields of industrial automation and robotics. The expansion modules can be installed locally or remotely, providing greater flexibility and convenience.
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Model Positioning and Core Functions
Model Attribution
3BHE046836R0102 is an ABB internal part number corresponding to the GFD563A102 excitation controller (Unitrol series), used in synchronous generator excitation systems.
Functional Positioning: Serves as the core control unit of the excitation system, implementing generator voltage regulation, reactive power distribution, dynamic stability control, and protection functions.
Core Control Logic
Voltage Closed-Loop Control: Compares the generator terminal voltage with the setpoint and adjusts the excitation current to maintain voltage stability (accuracy ±0.5%).
PSS (Power System Stabilizer): Suppresses low-frequency oscillations (0.1-2 Hz) to improve grid stability.
Limiting Functions: Includes overexcitation limiting (to prevent rotor overheating), underexcitation limiting (to prevent loss of step), and V/Hz limiting (to protect stator insulation).
Key Technical Parameters
Parameter Category Technical Specifications
Input Signal – Generator Voltage: 100V AC (PT Secondary Side)
- Generator Current: 5A AC (CT Secondary Side)
- Excitation Current: 0-20mA DC
Output Signal – Excitation Current Command: 4-20mA DC
- Alarm/Trip Signal: Dry Contact (24V DC, 2A Capacity)
Control Accuracy – Voltage Regulation Error: ≤±0.3% (Steady State)
- Dynamic Response Time: ≤50ms (Recovers to 90% after a ±10% voltage change)
Environmental Adaptability – Operating Temperature: -20°C to +60°C
- Humidity: ≤95% RH (non-condensing)
- Protection Rating: IP20 (Indoor Installation)
Communication Interface – Ethernet: 100Mbps, supports IEC 61850/Modbus TCP
Serial Port: RS485 (optional, supports Modbus RTU)
Power Requirements: Input Voltage: 220V AC ±10% (50/60Hz)
Power Consumption: ≤150W
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Hardware Structure and Redundancy Design
Modular Architecture
Main Control Board (CPU): Dual ARM Cortex-A9 processors running a real-time operating system (RTOS) implement control algorithms and logic.
Signal Conditioning Board: Isolates input/output signals, with interference immunity ≥10kV (pulse group interference test).
Power Supply Board: Dual redundant power supplies with automatic switchover in the event of a failure in either power supply (switching time <5ms).
Redundant Configuration (Optional)
Hot Standby Mode: Two sets of 3BHE046836R0102 modules operate in parallel, ensuring seamless master/slave switchover (data synchronization via optical fiber).
Two-out-of-three Logic: Critical signals (such as voltage measurement) utilize triple redundancy to prevent malfunctions caused by single-point failures.
Typical Application Scenarios
Synchronous Generators in Thermal Power Plants
600MW Supercritical Units: Combined with the UNITROL 6000 excitation system, achieve high-precision voltage regulation (error <0.2%).
Peak-shaving operation: Rapidly responds to load changes (e.g., voltage fluctuation ≤±1.5% when the load suddenly changes to 50%).
Hydropower plant pumped storage units
Generation/pumping mode switching: Dynamically adjusts excitation parameters to suppress voltage fluctuations caused by water hammer.
Black start capability: When grid support is unavailable, generators can be started through excitation control to restore local power supply.
Renewable energy support
Wind power hydrogen production project: Provides excitation control for the synchronous generators powering the electrolyzers, ensuring stable hydrogen production.
PV energy storage system: Enhances grid inertia response capabilities by simulating the characteristics of synchronous generators.
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Common Faults and Solutions
Fault Symptoms, Possible Causes, and Solutions
Large voltage fluctuations. PID parameters are out of adjustment, and the PT wiring is loose. Recalibrate the PT/CT and adjust the PID parameters using ABB ExpertOptimizer software (Kp=0.8, Ki=0.05, Kd=0.1).
Unable to adjust the excitation current. Power module failure, trigger pulse loss. Check the thyristor rectifier bridge and replace the damaged module; verify the trigger pulse waveform using an oscilloscope (frequency = 50Hz, pulse width = 1ms).
Communication interruption. Network cable is damaged, and there is an IP address conflict. Check the physical connection and configure a static IP address. Update the firmware to the latest version (e.g., V3.12).
Self-diagnostic alarm (E002): Power module overtemperature. Clean the cooling fan and check the ambient temperature (must be ≤45°C). Replace the power board fan (model: ABB 5SYA2045).
Maintenance and Spare Parts Management
Regular Maintenance Items
Every 6 Monthly: Clean dust from the module interior and check the tightness of the terminal blocks (torque value: 0.6 Nm).
Yearly: Calibrate the PT/CT ratio and test the PSS function (using ABB TestManager software to inject a 0.5 Hz oscillation signal).
Spare Parts Strategy
Critical Spare Parts: We recommend stocking one complete module (including the main control board, power board, and signal conditioning board), with an inventory cycle of ≤ 2 years.
Refurbished Modules: For low-cost replacements, ABB certified refurbished parts are available (test reports and a 6-month warranty are required).
Firmware Upgrade
Download the latest firmware (e.g., V3.15) through the ABB Ability™ Remote Diagnostics Platform. Back up configuration parameters before upgrading.
Note: Do not disconnect the power supply during the upgrade process, as this may cause permanent damage to the module.
Safety Precautions
Disconnect the power supply before operation: During maintenance, the input power must be disconnected and a “Do Not Close” sign must be displayed.
Anti-static measures: Wear an anti-static wrist strap when replacing modules to avoid damage to electronic components.
Compliance: Ensure the module complies with local grid regulations (e.g., IEEE STD 421.5, GB/T 7409.3).
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Product Positioning and Series
Module Model: GFD563A102 (AC 800PEC Series Core Controller Module) is designed for industrial automation, power electronics, and process control. It integrates high-speed control (e.g., FPGA tasks as low as 25ns) with low-speed PLC task processing capabilities, supporting field logic control (LCI), motion control, logic control, and data acquisition.
Series: Part of ABB’s AC 800PEC series and ControlIT product line, it focuses on integrating high-speed power electronics control with low-speed process control.
Application Scenarios: Suitable for power generation, transmission systems, and industrial automation (e.g., generator excitation control and power conversion equipment), supporting both high and low voltage scenarios.
Technical Specifications
Electrical Parameters:
Input Voltage: 400VAC
Output Voltage: 0-400VAC
Output Current: 2.3A
Frequency: 50/60Hz
Control Mode: LCI (Local Control Interface)
Performance:
High-Speed Tasks: FPGA Task Cycle ≤ 25 nanoseconds, Matlab/Simulink Task ≤ 100 microseconds
Low-Speed Tasks: Conventional Control Logic ≤ 1 millisecond
I/O Response: Analog/Digital Conversion Cycle 25μs, Low-Speed I/O Cycle 10ms
Features
Dual-Core Architecture: Integrates high-speed control (power electronics) and low-speed process control (traditional PLC tasks), eliminating separate system requirements.
Communication Capabilities:
Two Ethernet ports (for connecting to the factory network, programming tools, and other devices)
RS-232/RS-422 serial ports (for local panel/terminal connections)
Up to two AnyIO ports (supports CEX bus and AnyBus-S modules, compatible with major fieldbuses)
Fiber optic link (inter-module communication, no electrical connections)
Scalability: Supports 36 bidirectional fiber optic PowerLinks, with a modular design to accommodate diverse I/O configurations.
Technical Specifications
I/O Capacity:
Base Configuration: 62 I/O combinations (30 digital inputs including two shaft encoders, two analog inputs, 28 digital outputs, and two high-speed digital outputs).
Expandability: Expandable up to 1024 I/O points via local/remote expansion modules (up to 1000m).
Voltage Range: Input: 85V AC-264V AC or 24V DC; Output: 0-380V AC/0-400V AC or 5V DC-60V DC, output current up to 10A, power approximately 100W.
Hardware Configuration:
Processor: Multi-core CPU (2.5GHz) or PowerPC 405 (200MHz), with 4GB DDR3 RAM or 256MB RAM + 512MB Flash.
Storage: 8GB eMMC, supporting non-volatile program/data storage.
Communication Interfaces: RS232, RS485, Ethernet, PROFINET DP, CAN, supporting Modbus, CANopen protocols, and third-party Anybus-S bus modules.
Environmental Adaptability:
Operating Temperature: -20°C to +60°C, IP67/IP65 protection rating, suitable for harsh industrial environments.
Mechanical Specifications: Dimensions: 380 × 142 × 73.5 mm, weight: approximately 1.54 kg.
Core Functions and Application Scenarios
Control Performance:
Cycle times as low as 100 μs (fast tasks), support for real-time control development using MATLAB/Simulink, and an integrated FPGA for high-speed algorithm processing.
Compatible with the ABB 800xA system, it supports IEC 61131-3 standard programming (Control Builder M tool) and automatic Simulink code generation.
Programming and Development Environment
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I. Core Identity and Technical Specifications
Module Model and Positioning
This module belongs to the AC 800PEC series of high-performance controllers. Serial number 3BHE046836R0102 corresponds to hardware version GFD563A102. Designed specifically for power electronics and industrial automation, it integrates high-speed control (cycle times as low as 100μs) with low-speed logic processing capabilities, supporting field logic control (LCI), motion control, and data acquisition.
Hardware Configuration: Multi-core CPU (2.5GHz) or PowerPC 405 (200MHz), 4GB DDR3 RAM/256MB RAM + 512MB Flash, 8GB eMMC storage, and support for non-volatile storage.
Communication Interfaces: Supports RS232, RS485, Ethernet, PROFINET DP, and CAN bus. Compatible with Modbus, CANopen protocols, and third-party Anybus-S bus modules, it enables fast I/O data exchange (<100μs) via fiber optic links.
II. Core Functions of Excitation Control
Voltage and Reactive Power Control
Maintains constant generator terminal voltage (fluctuation ≤ ±0.5%), precisely adjusts excitation current using a PID algorithm, optimizes reactive power distribution between paralleled units, avoids overload or underload, and improves grid stability.
In the event of a grid fault, the forced excitation function is triggered to quickly restore system voltage; in the event of an internal generator fault, rapid deexcitation is performed to reduce the risk of equipment damage.
Dynamic Response and Protection Mechanism
Integrated overcurrent, undervoltage, and overvoltage protection software packages support fault self-diagnosis and redundant switching (a dual-channel active/standby design automatically switches to the backup channel in the event of a fault, reducing downtime).
Passing electromagnetic compatibility (EMC) testing, it effectively shields against common-mode interference in industrial environments and ensures signal transmission stability.
Technical Parameters
Parameter Category Specific Specifications
Input Voltage: 85V AC to 264V AC (Some models support 24V DC)
Output Voltage: 0 to 380V AC / 0 to 400V AC; or 5V DC to 60V DC (configurable)
Maximum Output Current: 10A, Output Power: Approximately 100W
Dimensions: 380mm Deep × 73.5mm Height × 142mm Width, Weight: Approximately 1.54kg
Processor and Storage: Multi-core processor (2.5GHz) or PowerPC 405 (200MHz); Memory: 4GB DDR3 RAM / 256MB RAM + 512MB Flash; Storage: 8GB eMMC
Communication Interfaces: RS232, RS485, Ethernet, PROFINET DP, CAN; supports industrial protocols such as Modbus and CANopen.
Environmental adaptability: Operating temperature -10°C to +50°C (or -20°C to +60°C); IP67/IP20/IP65 protection.
I/O expansion supports 62 analog/digital inputs and outputs (30 digital inputs + 28 analog inputs + 2 digital outputs + 2 high-speed outputs), expandable to 1024 I/O points.
Core Functions and Features
Precise Control: Utilizes a high-performance processor and advanced algorithms to achieve fast response and precise motion trajectory planning, meeting the requirements of highly dynamic scenarios.
Comprehensive Protection: Built-in multiple protection mechanisms, including overcurrent, overvoltage, and overtemperature, ensure safe operation of the device. Fault diagnosis and alarm functions are supported (e.g., abnormal speed and voltage fluctuations).
Flexible Communication: Compatible with multiple industrial protocols, it seamlessly integrates with PLCs, SCADA systems, and monitoring platforms, supporting remote configuration and status monitoring.
Expandable Compatibility: Parameter configuration is performed using ABB Control Builder or Automation Builder software; expansion modules (such as adding I/O points or function modules) are supported.
Industrial-grade Design: Utilizing high-quality electronic components and advanced manufacturing processes, it withstands harsh environments (such as high temperature, high humidity, and electromagnetic interference) to ensure long-term stable operation.
III. Application Scenarios and Case Studies
Power Industry
Power Generation Scenarios: Maintaining generator voltage stability and improving grid connection efficiency in coal-fired, gas-fired, and hydropower generation scenarios; coordinating with steam turbine speed regulators to optimize the dynamic balance between power generation and load.
Case Study: The Xiluodu Right Bank Power Station utilizes the ABB UNITROL 6800 excitation system, combined with the AC 800PEC controller, to achieve high-precision excitation control and ensure grid stability.
Industrial Automation
Applications include robotic motion control, CNC machine tool control, synchronous control of packaging machinery, and power factor regulation for arc furnaces, rolling mills, and other equipment to reduce reactive power losses.
Process Industries
Enables process monitoring and optimization in the chemical, metallurgical, and intelligent manufacturing industries, such as furnace top voltage monitoring and electrode speed limit protection.
IV. Programming and Development Environment
Toolchain Support
IEC 61131-3 Standard Programming: Ladder diagrams and function block diagrams are supported through the ABB Control Builder M tool, supporting modular design and reducing hardware redundancy.
MATLAB/Simulink Integration: Model-based design enables a seamless transition from simulation to hardware deployment, supporting FPGA algorithm acceleration (such as protocol processing and high-speed control loops).
System Integration: Deep integration with the ABB 800xA system and compatibility with the OPC UA standard facilitates interaction with DCS/PLC/SCADA systems, supporting remote parameter adjustment and predictive maintenance.
V. Installation and Maintenance Key Points
Physical Configuration
The front panel provides LAN, SVGA, COM ports, USB, and status LEDs. The rear panel supports PMC and IDE drive expansion, requiring dedicated converter boards (such as the VMIACC-0562) to connect to industry-standard interfaces.
The modular architecture supports flexible configuration of I/O modules (such as the S800 series) to meet the needs of applications of varying scales.
Environmental Adaptability
With an operating temperature range of -20°C to +60°C, IP67/IP65 protection, and shock and vibration resistance tested, it's suitable for harsh industrial environments.
The power supply design supports a wide input voltage range of 110-240V and requires a shielded isolation transformer and low-pass filter to reduce interference.
Maintenance and Diagnostics
The onboard BIOS supports CMOS configuration (such as setting the hard drive type to AUTO), stores key parameters in non-volatile SRAM, and supports a watchdog timer and system fault recovery.
VI. Compatibility and Scalability
System Compatibility: Supports integration with third-party devices (such as DCS800 and Siemens PLCs) via standard protocols (such as OPC UA and Modbus), reducing maintenance costs.
Expansion capability: Expand the field bus module through the AnyBus-S slot, support optical fiber links to achieve high-speed communication between modules (100μs level), and can be expanded to a maximum of 1024 I/O points.
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General Information
Product ID:
3BHE039770R0102
ABB Type Designation:
–
Catalog Description:
PP D539 A102: AC 800PEC Contr. Device
Long Description:
PP D539 A102: AC 800PEC Contr. Device
Additional Information
ABB Type Designation:
–
Country or Territory of Origin:
Switzerland
China
Customs Tariff Number:
85371092
Frame Size:
Undefined
Gross Weight:
0 kg
Invoice Description:
PP D539 A102: AC 800PEC Contr. Device
Made To Order:
No
Minimum Order Quantity:
1 piece
Order Multiple:
1 piece
Package Level 1 Gross Weight:
0 kg
Package Level 1 Units:
1 piece
Part Type:
New
Product Name:
–
Product Net Depth / Length:
142 mm
Product Net Height:
145.5 mm
Product Net Weight:
0.84 kg
Product Net Width:
71 mm
Product Type:
Undefined
Quote Only:
No
Selling Unit of Measure:
piece
Stocked At (Warehouses):
Baden, Switzerland
WEEE Category:
Product Not in WEEE Scope
Carrey –
The GFD563A102 3BHE046836R0102 excitation central processing unit module supports a variety of analog and digital input and output combinations, and can process multiple signals simultaneously. The specific input and output configuration may include digital input, analog input, digital output, and high-speed digital output, etc., to meet complex control requirements. At the same time, through additional expansion modules, the configuration of this module can be further expanded to adapt to more complex application requirements in the fields of industrial automation and robotics. The expansion modules can be installed locally or remotely, providing greater flexibility and convenience.
https://www.axcontroler.com/ABB/gfd563a102—excitation-central-processor-module—abb—3bhe046836r0102—gfd563a102