Description
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GFD563A102 3BHE046836R0102 Other names:
Excitation controller unit GFD563A102 3BHE046836R0102
GFD563A102 3BHE046836R0102 Central processor unit
Analog unit GFD563A102 3BHE046836R0102
Product Overview
Brand and series: This product belongs to the AC800PEC series controller of ABB.
Material code: GFD563A102 3BHE046836R0102 , which is the unique identifier of the product.
Category: PLC programmable controller, used in the field of industrial automation control.
Product Features
Structural form: Time-sharing management linearization, this structure helps to improve the processing efficiency and stability of the controller.
Output frequency: standard kHz, meeting the needs of general industrial automation control.
I/O points: analog output, with I/O modules such as SM1232, 4AO, etc., which can be flexibly configured to meet different control needs.
Installation method: plug and play, which simplifies the installation and debugging process and improves work efficiency.
Working voltage: standard voltage range, suitable for a variety of industrial environments.
Product certification: After original factory certification, the quality and reliability of the product are guaranteed.
Modular design: The AC 800PEC series adopts modular design, which is convenient for users to add or remove modules according to actual needs.
High performance: The control device has an extremely high processing speed and is suitable for occasions that require fast response and precise control.
Communication capability: Supports multiple communication protocols and interfaces, such as Ethernet, RS-232/RS-422 serial ports, etc., which is convenient for communication with other control devices and systems.
Programming environment: ABB Control Builder M programming environment based on IEC 61131-3 standard, and optimized rapid application code development environment based on MATLAB®/Simulink® and RealTime Workshop® provide users with powerful programming support.
Integration: AC 800PEC is fully integrated into ABB’s ControlIT software environment, which facilitates system integration and unified management.
Remote I/O expansion: ABB’s remote input/output (I/O) expansion units allow users to monitor and control equipment in decentralized locations. These expansion units can be connected to the main controller via Industrial Ethernet or other types of communication networks.
Rich communication interfaces: Provide multiple communication interfaces to support connection and communication with other devices, making it easy for users to build complex control systems.
Excellent connectivity:
Supports up to 36 bidirectional fiber optic PowerLinks.
It has two Ethernet ports for connecting to plant control networks, other processor modules, etc.
It provides RS-232/RS-422 serial ports for local process panels and service terminals.
Equipped with up to two onboard AnyIO ports for optical PowerLink and ABB S800 optical module bus.
Programming and Integration:
ABB Control Builder M programming environment based on IEC 61131-3 standard.
Can be integrated with MATLAB®/Simulink® and RealTime Workshop® to optimize rapid application code development.
Fully integrated into ABB’s ControlIT software environment.
Application and Optimization
Hardware Optimization: AC 800PEC hardware is optimized for power electronic control, and the optical connection between the controller and process I/O is used for fast peripheral I/O devices for control and measurement. Programs and data are stored in flash memory, without backup battery, compatible with standard ABB S800 I/O devices, suitable for field installation.
Software Programming: Programming based on ABB Control Builder M programming environment based on IEC 61131-3 standard. At the same time, it supports optimized rapid application code development based on MATLAB®/Simulink® and RealTime Workshop®.
Integrated environment: AC 800PEC is fully integrated into ABB’s ControlIT software environment for easy system management and monitoring.
Application areas
AC 800PEC control device GFD563A102 3BHE046836R0102 is widely used in industrial automation control fields that require high performance, high reliability and flexible configuration, such as power, petroleum, chemical, metallurgy and other industries. Its modular design allows the system to be expanded and upgraded according to actual needs to meet the changing needs of industrial automation.
Power electronics control: The control device is particularly suitable for the control of power electronic equipment, such as high-power rectifiers, micro turbines, wind turbines, traction drives and battery energy storage systems.
Industrial automation: In the field of industrial automation, AC 800PEC control devices can be used for monitoring and control of various industrial processes to improve production efficiency and product quality.
Company background
ABB company profile: ABB (Abb Co., Ltd.) is a global leading electrical and automation technology company headquartered in Zurich, Switzerland. Its business covers more than 100 countries around the world and has about 105,000 employees. ABB is committed to promoting technological innovation and industrial transformation, and providing customers with efficient, reliable and sustainable solutions.
ABB in China: ABB’s business in China began in 1907, and now has a full range of business activities in China, including R&D, manufacturing, sales and engineering services. ABB’s products and services are widely used in China’s industrial, commercial, power and public utilities fields, and have made important contributions to China’s national key project construction.
In summary, AC 800PEC control device GFD563A102 3BHE046836R0102 is a high-performance, modular programmable controller module launched by ABB, suitable for power electronic control and industrial automation and other fields. Users can choose to purchase according to actual needs and enjoy the powerful programming support and system integration services provided by ABB.
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Installation method: plug and play, which simplifies the installation and debugging process and improves work efficiency.
Working voltage: standard voltage range, suitable for a variety of industrial environments.
Product certification: After original factory certification, the quality and reliability of the product are guaranteed.
Modular design: The AC 800PEC series adopts modular design, which is convenient for users to add or remove modules according to actual needs.
High performance: The control device has an extremely high processing speed and is suitable for occasions that require fast response and precise control.
Communication capability: Supports multiple communication protocols and interfaces, such as Ethernet, RS-232/RS-422 serial ports, etc., which is convenient for communication with other control devices and systems.
Programming environment: ABB Control Builder M programming environment based on IEC 61131-3 standard, and optimized rapid application code development environment based on MATLAB®/Simulink® and RealTime Workshop® provide users with powerful programming support.
admin –
The GFD563A102 is the core control unit for the ABB AC 800PEC (Power Electronics Controller) system and belongs to an earlier version of the UNITROL 6000 series (a different iteration of the same series as the 3BHE046836R1102).
Core Positioning: Designed specifically for excitation control of synchronous generators, synchronous motors, and grid-connected renewable energy systems (such as wind power and photovoltaic hydrogen production), it supports high-precision voltage regulation, dynamic stability control, and multi-machine coordinated operation.
Core Control Logic
Multi-Mode Switching:
AVR Mode: Automatic Voltage Regulation (steady-state accuracy ±0.15%, slightly lower than the R1102 version).
PSS Mode: Integrated PSS2A/PSS2B algorithms to suppress low-frequency oscillations (0.1-2.5Hz).
V/Hz Limit Mode: Prevents stator core saturation (overvoltage protection threshold can be set to 1.1-1.2Un).
Power Factor Control: Maintains constant generator reactive power (suitable for phase-shifting or industrial motor applications).
Dynamic Response: Recovery time ≤ 50ms for a ±10% voltage change (20ms slower than the R1102 version).
https://www.weikunfadacai1.com/product/gfd563a102-ac-800pec-control-unit-abb-3bhe046836r0102-gfd563a102/
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Hardware Architecture and Technical Specifications
1. Modular Design
Module Type Functional Description
Main Control Unit (CPU): Single-core ARM Cortex-A9 processor, 800MHz, running the VxWorks 6.9 real-time operating system, supporting eight concurrent tasks.
The Signal Conditioning Board isolates input/output signals, with an anti-interference capability of ≥10kV (IEC 61000-4-5 standard) and supports eight analog inputs (12-bit ADC).
The Power Interface Board provides eight PWM outputs (driving IGBT bridge rectifiers), with a maximum output current of 15A and a switching frequency of 8kHz.
The Communication Module has a single Ethernet port (100Mbps) supporting Modbus TCP/IP and IEC 60870-5-103 protocols (non-redundant design).
The power module provides dual power supply (220V AC/110V DC), with a master-slave switchover time of <5ms (3ms slower than the R1102 version).
2. 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: 0-10A DC (Hall Sensor Input)
Output Signal - Excitation Current Command: ±10V DC (Corresponding to 0-10A)
- Alarm/Trip Signal: 24V DC Dry Contact (Capacity 3A)
Control Accuracy - Voltage Regulation Error: ≤±0.1% (Steady State)
- Dynamic Response Time: ≤50ms (Recovers to 95% after a ±10% voltage change)
Environmental Adaptability - Operating Temperature: -20°C to +60°C (Industrial Grade)
- Humidity: ≤90% RH (Non-Condensing)
- Protection Grade: IP42 (Dustproof and Waterproof)
Electromagnetic Compatibility Complies with IEC 61000-6-2 (Industrial Environment) standard (lacks power plant environment certification compared to R1102).
Software Functionality and Extensibility
Core Software Package
UNITROL 6000 Basic Suite: Integrates basic functions such as AVR, PSS, and limiters, and supports offline parameter tuning (configuration requires ABB PC Tool software).
AC 800PEC Legacy Module: Compatible with earlier UNITROL 5000 series protocols (such as CANopen communication).
Basic Security Toolkit: Supports AES-128 encryption and simple password policies (no RBAC role management).
Extended Function Limitations
No black start support: Requires an external diesel generator controller for automatic start.
Multi-machine coordination limitations: Supports up to 8 generators in parallel (synchronized via RS485 bus, latency <10μs).
No AI-assisted diagnosis: Relies on traditional threshold alarms (e.g., IGBT temperature >85°C triggers protection).
Typical Application Scenarios
Small and medium-sized thermal power plants/hydropower plants
300MW units: Combined with the UNITROL 6500 excitation system, achieves voltage regulation accuracy of ±0.12%, meeting GB/T 7409.3 standards.
Frequency Regulation Service: Participates in grid secondary frequency regulation through the PSS function (regulation range ±3% of rated power).
Industrial Synchronous Motors
Large Compressor Drives: Constant power factor operation (power factor ≥ 0.9) reduces reactive power losses (saving 15% compared to asynchronous motors).
Soft Start Control: Limits starting current (peak value < 2.5 times rated current) to extend equipment life. Early Renewable Energy Projects Wind Power Hydrogen Production Pilot: Provides excitation control for synchronous generators powering electrolyzers (power fluctuation < ±2%). Photovoltaic energy storage system: Simulates synchronous generator characteristics (inertia support time <2s) to improve grid stability. Common Faults and Solutions Fault Symptom: Possible Cause: Solution Large voltage fluctuation: PID parameters not optimized, loose PT wiring. Adjust the PID using the ABB PC Tool software (Kp=0.3, Ki=0.01, Kd=0.02); check the tightness of the PT/CT wiring. Unable to adjust the excitation current: Power module fault, trigger pulse loss. Use an oscilloscope to verify the PWM output waveform (frequency = 8kHz, pulse width = 0.8ms); replace the IGBT module (model: ABB 5SNA 0800N170100). Communication interruption: Network cable damaged, IP address conflict: Check the physical connection, configure a static IP address, and upgrade the firmware to V1.08 (supports DHCP conflict detection). Self-diagnostic alarm (E101): Power module overvoltage. Check input voltage (requires ≤264V AC); replace power board capacitors (model: Nichicon UPW1H221MHD). PSS function failure. Speed sensor signal drift. Calibrate sensor (accuracy ±0.2%); adjust PSS gain (recommended K=5). Maintenance and Spare Parts Management Regular Maintenance Items Every 6 months: Clean dust inside the module and check terminal tightness (torque value: 0.6Nm). Yearly: Calibrate PT/CT ratio and test PSS function (inject a 0.5Hz oscillation signal using ABB TestManager software). Every 2 years: Replace cooling fan filter and check capacitor capacity (replace if attenuation >15%).
Spare Parts Strategy
Key spare parts: It is recommended to stock one complete module (including main control board, power interface board, and power module). Inventory period ≤12 months.
Refurbished Modules: ABB certified refurbished parts are available (test reports and a 6-month warranty are required).
Firmware Upgrade
Firmware upgrades (e.g., V1.10) are available via ABB DriveManager software. Configuration parameters must be backed up before upgrading.
Note: Power must not be interrupted during the upgrade process, as this may permanently damage the module. A self-test must be performed after the upgrade (running time ≥ 5 minutes).
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Comparison with R1102
Features: GFD563A102 (R0102) 3BHE046836R1102
Processor Performance: Single-core ARM Cortex-A9 (800MHz) Dual-core ARM Cortex-A53 (1.2GHz)
Communication Redundancy: None Dual-redundant Ethernet (1000Mbps)
PSS Frequency Range: 0.1-2.5Hz, 0.1-3Hz
Dynamic Response Time: ≤50ms, ≤30ms
Operating Temperature Range: -20°C to +60°C, -40°C to +70°C
Firmware Update Method: Local Update (DriveManager), Remote Update (ABB Ability™)
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Common Faults and Solutions
Fault Symptoms, Possible Causes, and Solutions
Large voltage fluctuations. PID parameters are not optimized, and the PT wiring is loose. Adjust the PID using the ABB PC Tool (Kp=0.3, Ki=0.01, Kd=0.02); check the tightness of the PT/CT wiring.
Unable to adjust the excitation current. Power module fault. Trigger pulse loss. Use an oscilloscope to verify the PWM output waveform (frequency = 8kHz, pulse width = 0.8ms); replace the IGBT module (model: ABB 5SNA 0800N170100).
Communication interruption. Network cable is damaged. IP address conflict. Check the physical connection and configure a static IP address. Upgrade the firmware to V1.08 (supports DHCP conflict detection).
Self-diagnostic alarm (E101): Power module overvoltage. Check the input voltage (must be ≤264V AC); replace the power board capacitor (model: Nichicon UPW1H221MHD).
PSS function fails. Speed sensor signal drifts. Calibrate the sensor (accuracy ±0.2%); adjust PSS gain (K=5 is recommended).
admin –
The GFD563A102 is the core control unit for the ABB AC 800PEC (Power Electronics Controller) system and belongs to an earlier version of the UNITROL 6000 series (a different iteration of the same series as the 3BHE046836R1102).
Core Positioning: Designed specifically for excitation control of synchronous generators, synchronous motors, and grid-connected renewable energy systems (such as wind power and photovoltaic hydrogen production), it supports high-precision voltage regulation, dynamic stability control, and multi-machine coordinated operation.
Core Control Logic
Multi-Mode Switching:
AVR Mode: Automatic Voltage Regulation (steady-state accuracy ±0.15%, slightly lower than the R1102 version).
PSS Mode: Integrated PSS2A/PSS2B algorithms to suppress low-frequency oscillations (0.1-2.5Hz).
V/Hz Limit Mode: Prevents stator core saturation (overvoltage protection threshold can be set to 1.1-1.2Un).
Power Factor Control: Maintains constant generator reactive power (suitable for phase-converter or industrial motor applications).
Dynamic Response: Recovery time ≤ 50ms for a ±10% voltage change (20ms slower than the R1102 version).
Hardware Architecture and Technical Specifications
1. Modular Design
Module Type Functional Description
Main Control Unit (CPU): Single-core ARM Cortex-A9 processor, 800MHz, running the VxWorks 6.9 real-time operating system, supporting 8-task parallel processing.
The signal conditioning board isolates input/output signals, has an anti-interference capability of ≥10kV (IEC 61000-4-5 standard), and supports 8 analog inputs (12-bit ADC).
The power interface board provides 8 PWM outputs (driving the IGBT bridge rectifier), with a maximum output current of 15A and a switching frequency of 8kHz.
The communication module has a single 100Mbps Ethernet port, supporting Modbus TCP/IP and IEC 60870-5-103 protocols (no redundancy).
The power module offers dual power supply (220V AC/110V DC), with a master-slave switchover time of <5ms (3ms slower than the R1102 version).
2. 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: 0-10A DC (Hall Sensor Input)
Output Signal - Excitation Current Command: ±10V DC (Corresponding to 0-10A)
- Alarm/Trip Signal: 24V DC Dry Contact (Capacity 3A)
Control Accuracy - Voltage Regulation Error: ≤±0.1% (Steady State)
- Dynamic Response Time: ≤50ms (Recovers to 95% after a ±10% voltage change)
Environmental Adaptability - Operating Temperature: -20°C to +60°C (Industrial Grade)
- Humidity: ≤90% RH (Non-Condensing)
- Protection Grade: IP42 (Dustproof and Waterproof)
Electromagnetic Compatibility Complies with IEC 61000-6-2 (Industrial Environment) standard (lacks power plant environment certification compared to R1102).
Software Functionality and Extensibility
Core Software Package
UNITROL 6000 Basic Suite: Integrates basic functions such as AVR, PSS, and limiters, and supports offline parameter tuning (configuration requires ABB PC Tool software).
AC 800PEC Legacy Module: Compatible with earlier UNITROL 5000 series protocols (such as CANopen communication).
Basic Security Toolkit: Supports AES-128 encryption and simple password policies (no RBAC role management).
Extended Function Limitations
No black start support: Requires an external diesel generator controller for automatic start.
Multi-machine coordination limitations: Supports up to 8 generators in parallel (synchronized via RS485 bus, latency <10μs).
No AI-assisted diagnosis: Relies on traditional threshold alarms (e.g., IGBT temperature >85°C triggers protection).
Typical Application Scenarios
Small and medium-sized thermal power plants/hydropower plants
300MW units: Combined with the UNITROL 6500 excitation system, achieves voltage regulation accuracy of ±0.12%, meeting GB/T 7409.3 standards.
Frequency Regulation Service: Participates in grid secondary frequency regulation through the PSS function (regulation range ±3% of rated power).
Industrial Synchronous Motors
Large Compressor Drives: Constant power factor operation (power factor ≥ 0.9) reduces reactive power losses (saving 15% compared to asynchronous motors).
Soft Start Control: Limits starting current (peak value < 2.5 times rated current), extending equipment life.
admin –
Early Renewable Energy Projects
Wind Power Hydrogen Production Pilot: Provide excitation control for the synchronous generator powering the electrolyzer (power fluctuation <±2%). Photovoltaic Energy Storage System: Simulate the characteristics of a synchronous generator (inertia support time <2s) to improve grid stability. Maintenance and Spare Parts Management Regular Maintenance Items Every 6 months: Clean dust inside the module and check the tightness of the terminal blocks (torque value: 0.6Nm). Yearly: Calibrate the PT/CT ratio and test the PSS function (using ABB TestManager software to inject a 0.5Hz oscillation signal). Every 2 years: Replace the cooling fan filter and check the capacitor capacity (replace if attenuation >15%).
Spare Parts Strategy
Key Spare Parts: It is recommended to stock one complete module (including the main control board, power interface board, and power module), with an inventory cycle of ≤12 months.
Refurbished Modules: ABB certified refurbished parts are available (test report and 6-month warranty required).
Firmware Upgrade
Upgrade the firmware (e.g., V1.10) using ABB DriveManager software. Back up the configuration parameters before upgrading.
Note: Do not power off during the upgrade process, as this may permanently damage the module. A self-test must be performed after the upgrade (running time ≥ 5 minutes).
admin –
GFD563A102 | AC800PEC Control Unit | ABB | 3BHE046836R0102 Comprehensive Analysis
Core Positioning and Technical Features
System Affiliation: This module belongs to ABB’s AC800PEC high-end control system, order number 3BHE046836R0102. It is a core module for fiber-optic communication and industrial I/O control. It supports modular expansion up to 1024 I/O points and is compatible with S800 I/O modules and third-party devices (such as Siemens PLCs), making it suitable for industrial scenarios such as power generation, petrochemicals, and metallurgy.
Hardware Design:
Physical Parameters: Dimensions: approximately 13.6 cm × 13.6 cm × 10.6 cm, weight: 2.64 kg, IP20 protection rating, operating temperature: -25°C to +60°C, suitable for indoor and light industrial environments.
Electrical Parameters: Supports 100 Mbps full-duplex fiber optic communication (multimode ≤ 2 km, single-mode ≤ 40 km). SC/ST interface type, compatible with both multimode and single-mode fiber. Operating voltage: 24V DC/110-240V AC. Power consumption: ≤ 5W.
Interfaces and Communications: Compatible with Ethernet, Modbus TCP, OPC UA, Profibus DP, IEC 61850, and other protocols. Built-in redundant dual ports support ring network construction and HSR/PRP redundancy protocols.
Core Functions and Application Scenarios
Core Functions:
Communication and Data Transmission: Enables long-distance, high-reliability communication between stations, supports electrical-to-optical signal conversion, and is suitable for scenarios such as power grid monitoring and SCADA systems.
Control and Expansion: Supports motion control, logic control, and data acquisition. It integrates 30 digital inputs (including two shaft encoders), two analog inputs, 28 digital outputs, and two high-speed digital outputs. It can be expanded to 1024 I/O points via expansion modules.
Protection and Diagnostics: Built-in overcurrent, overvoltage, and overtemperature protection, with LED status indicators and a remote diagnostic interface, compatible with ABB Control Builder M/Automation Builder configuration tools.
Application Scenarios:
Power Industry: Substation automation, dynamic reactive power compensation in HVDC converter stations, grid monitoring, and excitation system control.
Industrial Automation: Metallurgical rolling mill control, petrochemical process control, rail transit traction motor control, and smart factory production line coordination.
Special Applications: Marine propulsion systems, grid-connected inverters for renewable energy, arc furnace power factor optimization, and process optimization for municipal wastewater treatment plants.
Installation and Maintenance Recommendations
Installation Specifications: Follow DIN rail mounting standards, ensure unobstructed heat dissipation, and avoid sources of electromagnetic interference (such as high-power motors). An independent overspeed protection device is required, complying with EMC standards (such as EN50082-2).
Maintenance Tips: Regularly check connector oxidation, capacitor aging, and cooling fan status; perform firmware upgrades every two years to optimize algorithms. Unauthorized modifications may void the warranty. Troubleshooting can quickly locate issues using LED indicators (such as RUN/ERR). A solid red light indicates a hardware failure and requires contacting the vendor’s technical support.
Compatibility Verification: Verify compatibility with the ABB AC800PEC backplane system, S800 I/O modules, and third-party devices to avoid configuration errors.