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PPD113B03-26-100110 3BHE023584R2634 Other names:
Input/output module PPD113B03-26-100110 3BHE023584R2634
PPD113B03-26-100110 3BHE023584R2634 Control motherboard
Analog module PPD113B03-26-100110 3BHE023584R2634
PPD113B03-26-100110 3BHE023584R2634 Excitation System Controller
The PPD113B03-26-100110 3BHE023584R2634 excitation control board is the core component used to control the generator excitation system. The main function of the excitation system is to provide DC excitation current to the generator to establish and maintain the generator’s magnetic field, thereby controlling the output voltage and current of the generator. The excitation control board is responsible for monitoring and controlling the operating status of the excitation system, ensuring that the generator can operate stably and efficiently.
The PPD113B03-26-100110 3BHE023584R2634 excitation control board usually has the following functions:
Excitation current control: Automatically adjust the magnitude and phase of the excitation current based on the operating status of the generator and the needs of the power grid, in order to maintain the terminal voltage and power factor of the generator within the set range.
Stability control: Monitor the operating status of the generator, suppress oscillations and instability by adjusting the excitation current, and ensure the stable operation of the generator.
Protection function: It has protection functions such as overcurrent, overvoltage, undervoltage, frequency deviation, etc. When abnormal conditions are detected, it can quickly cut off the excitation current to protect the generator and excitation system from damage.
Fault diagnosis and monitoring: By collecting and processing various sensor signals, the operating status of the excitation system is monitored in real time, and fault diagnosis information is provided to help operators quickly locate and solve faults.
Communication and interface functions: Communicate and interface with other control systems of the generator, such as automatic voltage regulators, automatic power factor controllers, etc., to achieve collaborative control and optimized operation of the entire power generation system.
The PPD113B03-26-100110 3BHE023584R2634 excitation control board usually adopts advanced control algorithms and microprocessor technology, with high automation and intelligence characteristics. It can be customized according to different types of generators and grid requirements to meet specific operational requirements. In the power system, the PPD113B03-26-100110 3BHE023584R2634 excitation control board is one of the key components to ensure the safe, stable, and economical operation of the generator.
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admin –
Communication and interface functions: Communicate and interface with other control systems of the generator, such as automatic voltage regulators, automatic power factor controllers, etc., to achieve collaborative control and optimized operation of the entire power generation system.
admin –
Material Ordering Model: 3BHE023584R2634
ABB Original ERP Material Code, the only official model for procurement, customs declaration, inventory, and after-sales maintenance.
Hardware Board Series Model: PPD113B03
Board hardware series name, suffix -26-100110 is the version/configuration sub-number.
Full Name Identifier: PPD113B03-26-100110 | 3BHE023584R2634
Equipment Category: Excitation control board
2. Basic Product Information
Brand Ownership
ABB UNITROL series synchronous generator excitation system core control board, suitable for excitation control cabinets of thermal power, hydropower, and gas turbine generator sets.
Core Functions
Generate excitation current closed-loop regulation to maintain stable generator terminal voltage;
Power factor/reactive power regulation, over-excitation/under-excitation limiting, and V/Hz limiting protection logic;
Acquisition of PT voltage, CT current, and rotor excitation feedback signals;
Communication with the main control unit for fault diagnosis, alarm, and waveform recording signal output;
Integrated thyristor power unit trigger control.
3. Model Segment Explanation
PPD113B03: Basic model number of the board, representing the hardware platform of the excitation regulation main control board.
-26: Hardware PCB version batch.
-100110: Firmware program version, factory functional configuration parameters.
3BHE023584R2634: ABB 3BHE series industrial control spare parts part number, with R2634 at the end corresponding to the complete configuration version.
4. Application Scenarios
Standard motherboard for ABB Unitrol 5000 / Unitrol 6000 excitation cabinets;
Excitation control systems for large and medium-sized steam turbine generators, hydro turbine generators, and diesel generator units;
High-power synchronous units in power plants, self-owned power stations, and metallurgical self-owned power plants.
Firmware Upgrade Completion Determination Process for PPD113B03-26-100110 (3BHE023584R2634)
This board belongs to the UNITROL 5000/6000 excitation system AC800PEC controller. The determination involves 4 main steps: reading the current firmware → verifying hardware compatibility → matching system operating conditions/faults/requirements → referring to the ABB official upgrade announcement. Each step is indispensable.
Step 1: Reading Current Firmware and Hardware Versions (3 Methods)
Method 1: Online Reading via Programming Software (Most Standard, Automation Builder / Unitrol Tool)
Connect your computer to the AC800PEC controller in the excitation cabinet via Ethernet, ensuring the IP address is on the same network segment.
Scan online devices using the software and select the PPD113B03 unit.
Go to Device Information / Identification and obtain two sets of key numbers:
Hardware PCB Version: PPD113B03-26 (board silkscreen suffix)
Firmware Application Version: 100110 (last 6 digits of the model number, indicating the currently running program version)
Simultaneously record the firmware of all system boards: power trigger board, I/O board, and communication board. All boards must be compatible.
Method 2: Local Viewing via Excitation HMI Panel
Front-side touchscreen → System Information / Maintenance Page → Controller Software Version. The PPD113 firmware number will be displayed directly.
Method 3: Offline Nameplate Identification (Spare Parts / When Disassembled and Without Power)
Complete Model Number on Board Side Label: PPD113B03-26-100110
-26 = PCB Hardware Version (Hardware-level limit on the highest supported firmware)
-100110 = Factory-installed Firmware Version
Important: The hardware suffix (-26) determines the maximum firmware that can be flashed. Versions higher than the hardware support version will result in bricking, pulse loss, and excitation failure.
II. Step Two: Hardware Compatibility Verification (Prerequisite for Upgrade)
Hardware Confirmation: The PPD113B03-26 PCB version only supports the corresponding 26 series firmware branch and cannot be flashed with -22/-24/-28 branch firmware.
Part Number Matching: The original firmware package 3BHE023584R2634 must include the R26xx version identifier.
Dual-Cabinet Redundancy Verification: The firmware versions of the two PPD boards for dual-redundant excitation must be completely identical. A version difference of ≥1 generation will cause master/slave switching failure, voltage oscillation, and false tripping.
Matching Power Units: The firmware versions of the thyristor trigger board and current sampling board must be compatible with the target new version. Upgrading a single board will result in trigger timing mismatch and excitation current distortion.
Compatible Power Units: The firmware versions of the thyristor trigger board and current sampling board must be compatible with the target new version. Upgrading a single board will result in trigger timing mismatch and excitation current distortion. III. Step 3: Determine 5 Scenarios Where an Upgrade is “Required” (Upgrade Recommended if any one of these criteria is met)
1. Existence of Known Firmware Bugs as Officially Announced by ABB (Forced Priority Upgrade)
Typical High-Frequency Defects in Older Firmware Versions of PPD113B03 (Included in Lower Versions of the Same Generation as 100110):
LVRT Low Voltage Ride-Through Logic Failure under Grid Disturbances, Unit Prone to Grid Disconnection;
V/Hz Limit and Over/Under Excitation Limit Logic Calculation Deviations, Frequent Reactive Power Exceeding Limit Alarms;
Intermittent Communication Disconnections (Modbus/Profibus/ABB Ability), Loss of Waveform Recordings;
Pulse Blocking and Significant Voltage Fluctuations at the Generator Terminal During Dual Redundancy Switching;
Parameter Area Verification Errors After Power-Off Restart, Random Software Fault Alarms.
Operation: Contact ABB Power Plant Technical Support and provide PPD113B03-26-100110 to retrieve the corresponding firmware defect list.
2. Continuous Reproduction of Software-Related Faults on-site (Hardware Inspection Reveals No Abnormalities)
The fault persists even after power outages, board replacements, CT/PT wiring verification, and 24V power supply replacement:
The controller continuously reports Watchdog resets, indicating software abnormalities;
The excitation regulation PID controller exhibits periodic oscillations, which are not improved by parameter modifications;
Fault waveform recordings are incomplete, and protection action timings are disordered;
Remote computer data reading is intermittent, and register values fluctuate.
3. System Function Upgrades / New Grid Standards
The grid has added requirements for Low Voltage Ride-Through (LVRT), High Voltage Ride-Through (HVRT), and damped oscillation control; the old firmware does not support the corresponding algorithms;
New AGC/AVC reactive power dispatch, energy storage coordinated control, and remote communication protocols have been added;
Unit expansion and excitation power unit upgrades have been implemented, with the new firmware adapting to a larger excitation current range.
4. Firmware Incompatibility After Spare Part Replacement (Most Common Field Issue)
Old board firmware 100110, replaced with a new spare board firmware of higher 100130/100140:
Symptoms: Abnormal power-on communication, reactive power regulation deviation, protection malfunction;
Determination: Firmware must be unified, downgraded or upgraded to the same version.
Redundant cabinet with mixed old and new boards: Inconsistent firmware between the two boards leads to failed switching tests; forced upgrade to unified firmware is necessary.
5. Termination of ABB Lifecycle Technical Support
Lower version firmware patching and maintenance have ceased; no fault repair solutions are available. The manufacturer recommends upgrading to a long-term stable maintenance version.
IV. Step Four: Determining Scenarios Where “No Upgrade Required” (Blind Upgrades Are Not Recommended)
The following conditions must be met to maintain the existing 100110 firmware without upgrading:
The unit has been operating stably for ≥1 year, with no software alarms, no oscillations during regulation, and normal switching;
The grid standards have not been updated, and no new LVRT/dispatch functions are required;
All boards in the excitation cabinet have unified firmware, and redundancy switching tests have passed;
There are no reproducible intermittent crashes, communication interruptions, or protection malfunctions;
The hardware PCB version (-26) does not support higher firmware, and upgrading carries the risk of underlying hardware incompatibility;
The power plant has no downtime window; upgrading requires a complete unit shutdown, and the benefits are lower than the downtime costs.
V. Key Verification Checklist Before Upgrade (To Avoid Excitation Runaway)
Request a firmware compatibility matrix from ABB to confirm the target firmware is compatible with the PPD113B03-26 hardware;**
Completely back up all current excitation parameters, limit curves, communication mappings, and waveform recording configurations;**
Perform offline bench testing (preferably with a shutdown test). If a bench is unavailable, conduct an no-load voltage boost test for verification;**
Confirm the upgrade failure rollback plan: retain the original firmware files and use a backup original version board;**
After Upgrade:** Conduct full tests including no-load voltage regulation, reactive power adjustment, master/slave switching, and simulated grid faults.
Quick Judgment Summary:
First, read the hardware version -26 and firmware version 100110;
Check ABB announcements for fatal bugs in this version;
Check for ongoing software faults/modification needs/spare part version mismatches on-site;
Hardware compatible, faulty/modification needed → Upgrade;
Stable operation, no modification, hardware does not support higher versions → Do not upgrade.
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admin –
Complete Material Number: PPD113B03-26-100110
ABB Order Part Number: 3BHE023584R2634
General Board Model: PPD113B03
Equipment Type: Excitation control board (generator excitation control board)
II. Product Classification and Application Scenarios
This board belongs to the ABB UNITROL series excitation control system, and is mainly used in the following generator sets:
UNITROL 6000 / UNITROL 5000 Fully Digital Excitation Regulator
Suitable for thermal power, hydropower, and gas turbine synchronous generator excitation cabinets
Core Functions: Excitation current regulation, AVR voltage closed-loop control, power factor/reactive power regulation, system stability control, fault protection logic operation
III. Core Functions
Automatic Voltage Regulation (AVR): Real-time acquisition of generator terminal voltage, closed-loop control of excitation output, and stabilization of generator bus voltage
Reactive Power/ Power Factor Control Mode: Dual-mode switching between constant reactive power and constant power factor
System Stabilizer (PSS): Suppresses low-frequency oscillations and improves grid parallel stability
Limitation and Protection Logic: Over-excitation limit, under-excitation limit, stator current limit, V/F low-frequency protection
Signal Acquisition Interface: Synchronous sampling channels for PT voltage and CT current
Communication Interaction: Data interaction with the excitation system main controller, HMI, and power plant DCS system
IV. Differentiation of Boards in the Same Series
PPD113B03 is the core excitation operation mainboard
The suffixes -26 and 3BHE023584R2634 are hardware version/configuration codes, determining the board firmware, sampling range, and terminal definitions. Different suffix versions are not directly interchangeable.
100110 This is the factory configuration code, corresponding to the standard synchronous generator general configuration.
V. Industry Applications
Core control units for excitation cabinets of large steam turbine generators, hydro turbine generators, and self-owned power plant units. These are power control spare parts; most are discontinued or brand-new spare parts from disassembled units, widely used for power plant maintenance and replacement.
VI. Supporting Spare Parts
Commonly Used Supporting Boards for Excitation Systems:
UFC921AE, UFC718AE, XVC768AE Signal Acquisition Boards
PCD231A Power Drive Trigger Board
3BHE0 Series Power Modules and I/O Terminal Boards
ABB PPD113B03 (3BHE023584R2634) Complete Field Application Cases
The PPD113B03 is the core motherboard of the AC 800PEC high-speed power electronic controller and the computing center of the UNITROL 6000 excitation system. It has been implemented in four main categories: generator excitation, flexible power grid transmission, industrial high-power drives, and marine engineering, covering domestic power plants, overseas power plants, and metallurgical and chemical engineering scenarios.
I. Thermal Power Steam Turbine Generator Sets (Mainstream Application in China)
Case Study 1: Excitation Retrofit Project for a 300MW Self-Supplied Cogeneration Plant in Northern China
Project Background
The original units were equipped with outdated UNITROL F analog excitation regulators. Spare parts were out of production, voltage regulation response was slow, and low-frequency oscillations in the power grid occurred frequently. All four 300MW steam turbine generators in the plant were simultaneously retrofitted to UNITROL 6000 fully digital excitation systems. The main control system uniformly adopted a dual-redundant configuration of PPD113B03-26-100110 (3BHE023584R2634) from ABB Group.
Core Functions of the Board:
25μs high-speed AVR closed-loop operation, achieving a steady-state voltage control accuracy of ≤0.2% at the generator terminals;
PSS2A power system stabilizer algorithm to suppress low-frequency oscillations in the regional power grid;
Multi-limit logic operation for overexcitation/underexcitation/V/F/stator current;
Communication and interaction with the power plant’s 800xA DCS, synchronizing devices, and fault recording equipment.
Improvement Results:
Original system voltage fluctuation ±1.2%, improved to ±0.15%; no instability alarms under grid disturbances, and a 95% annual reduction in excitation fault shutdowns; PPD113B03 dual-master seamless switching, zero unit trips in case of single-board failure.
Supporting Board Combination:
PPD113B03 main controller + UFC921AE sampling board + PCD231A thyristor trigger board + UNS power supply board. Case 2: New Excitation Cabinet for a 660MW Supercritical Thermal Power Unit in Southern China
Operating Condition: 660MW water-hydrogen-hydrogen cooled turbine generator, self-excited static excitation, single-unit dual-channel UNITROL 6000 Medium.
Selection Logic:
Large-capacity units experience significant grid disturbances. The PPD113B03, with its built-in FPGA hardware acceleration, provides a 4-fold faster excitation regulation response speed compared to older main controllers under short-circuit and load shedding conditions, meeting the requirements of the new grid connection guidelines for strong excitation multiple and regulation speed.
On-site Operation and Maintenance Features:
The PPD113B03 locally stores fault waveforms and excitation curves, allowing for one-click waveform export via HMI, significantly reducing fault diagnosis time; it also supports remote ABB Ability cloud diagnostics.
II. Hydropower/Pumped Storage Power Station Application Cases
Case 3: Batch Retrofitting of Multiple Run-of-Road Hydropower Stations in Tasmania, Australia
Project Overview
The Hydro Tasmania project involved the complete replacement of the outdated analog excitation systems for 11 turbine generators across 7 hydropower stations. All units were equipped with UNITROL 6000 controllers, using the PPD113B03 series (including this model – version 26 3BHE023584R2634) from ABB Group.
Hydropower-specific control logic (calculated by PPD113B03):
Adaptive excitation regulation for turbines under varying head and load conditions;
Automatic switching between two-way operating modes (generator/pumped motor operation) for pumped storage;
Electric braking logic and low-head start-up optimization algorithm;
Multi-unit reactive power co-operation and unified allocation of reactive power output within the station.
Environmental Adaptability Advantages
Wide temperature range: -25℃ to 70℃, no condensation faults in high-humidity reservoirs, resistant to moisture and water vapor corrosion.
Case Study 4: New 220MW Pumped Storage Power Station Project in China
Large water level differences between upper and lower reservoirs, frequent unit start-ups and shutdowns, peak shaving and frequency regulation; PPD113B03 provides fast response to AGC/AVC dispatch commands, meets grid frequency regulation assessment indicators, and dual redundancy configuration eliminates single-card failure shutdowns.
III. Gas-fired Combined Cycle Power Plant Case Study
Case Study 5: Coastal 2×9F 300MW Gas Turbine Combined Cycle Power Plant
Operating Challenges
Extremely rapid fluctuations in gas turbine load (frequent gas turbine valve operation), dynamic changes in waste heat boiler steam parameters, easily causing drastic fluctuations in generator voltage.
PPD113B03 Solution
Built-in variable parameter PID adaptive regulation, automatically switching control parameters to differentiate between three operating conditions: gas turbine no-load, base load, and peak shaving; rapid excitation function ensures voltage does not exceed limits during load shedding.
Supporting Systems
Hard-wiring + bidirectional communication linkage with the gas turbine MARK VI control system; tripping and start-up interlocking logic are all handled by the PPD113B03.
IV. Flexible Power Transmission (SVC/STATCOM) Case Study
Case 6: East China 500kV Substation SVC Static Var Compensator
Equipment Positioning
The substation dynamic var compensator, with its core control unit also using the AC800PEC platform PPD113B03, no longer uses generator excitation, but rather thyristor valve group rapid var regulation.
Board Functions:
Real-time acquisition of bus voltage and reactive power; microsecond-level control of thyristor conduction angle; suppression of bus voltage flicker and balancing of three-phase imbalance; support for stable grid-connected voltage in new energy power plants (wind and solar).
V. High-Power Drive Industrial Applications in Metallurgy:
Case 7: AC-AC Variable Frequency Main Drive Control System for a Large Steel Hot Rolling Mill
Scenario: 25MW rolling mill synchronous main motor; AC-AC variable frequency speed regulation + synchronous motor excitation integrated control; controller AC800PEC equipped with PPD113B03.
Control Content:
High-precision adjustment of synchronous motor excitation current to ensure stable rolling torque; suppression of voltage drop in the plant’s power grid caused by rolling mill impact loads, reducing production line breakage and scrap.
VI. Offshore Platform/Ship Power System Cases:
Case 8: Excitation Control of Main Generator on a South China Sea Offshore Oil Production Platform
Operating Conditions: Offshore diesel synchronous generator set; confined space, high salt spray, strong vibration, isolated grid operation (no large power grid support). PPD113B03 Compatibility Advantages
Certified for IEC60068 vibration and salt spray environments; features a dedicated islanded grid excitation algorithm to prevent voltage collapse during load surges (start-stop of high-power compressors); dual redundancy ensures uninterrupted power supply to the platform.
VII. Typical Cases of General Spare Parts Replacement and Repair (Most Common in Power Plant Operation and Maintenance)
Case 9: Replacement of a Single-Channel PPD113B03 in an Inland Self-Supplied Power Plant
Fault Phenomenon: The communication light on the original PPD113B03 motherboard flashes, AVR regulation is unstable, and it frequently reports “Main Control Verification Failure”;
Resolution: Purchase a spare part of the same model, PPD113B03-26-100110 / 3BHE023584R2634, replace it by hot-swapping while powered on, import the local excitation parameter configuration, and restore operation without disturbance within 5 minutes;
Important Notes:
The hardware version with the suffix -26 and the factory configuration code 100110 must be completely matched. Firmware versions with different suffixes and sampling ranges are incompatible; direct replacement will lead to excitation loss of control.
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