Description

ABB 3BHL000392R0101 Technical Specifications

Product Model:ABB 3BHL000392R0101

Manufacturer:ABB(a global leader in industrial automation and motor control)

Product Type:Industrial-grade synchronous motor excitation control module

Applicable voltage:DC 220-400V(wide voltage adaptability,suitable for different motor excitation requirements)

Rated excitation current:50A(continuous output),peak current 75A/10s(to address motor startup excitation surge)

Excitation regulation accuracy:±0.5%(ensures motor magnetic field stability and reduces speed fluctuations)

Control method:PID closed-loop control(supports manual/automatic switching to adapt to different operating conditions)

Protection functions:Overcurrent protection(triggered at 150%rated current),overtemperature protection(triggered at 110°C module temperature),undervoltage protection(triggered at 180V DC input),demagnetization protection(triggered when excitation current falls below 5%)Rated value trigger)

Applicable motors:Synchronous motors(power range 100-500kW,such as metallurgical roller motors and generator excitation windings)

Operating temperature range:-10°C to+65°C(no performance derating,requires control cabinet cooling)

Storage temperature range:-40°C to+85°C

Insulation class:Class H(180°C temperature resistance,excitation winding/module insulation)

Physical dimensions:220mm(width)×300mm(height)×70mm(depth)(suitable for standard control cabinet installation)

Weight:Approximately 5.2kg

Certifications:CE,UL 1004-1,IEC 60034-1(motor control safety and electromagnetic compatibility standards)

ABB 3BHL000392R0101 Product Overview

In synchronous motor systems,the excitation module is the”field regulator,”and the ABB 3BHL000392R0101 is an absolute”magnetic field stabilization expert.”This excitation control module,designed by ABB specifically for medium-and large-power synchronous motors,provides stable,adjustable DC current to the motor’s excitation winding,generating a strong magnetic field to synchronize the motor’s rotor.Ultimately,it drives magnetic field-dependent components like metallurgical roller tables,generators,and large fans,ensuring they don’t malfunction due to unstable excitation or demagnetization.

Don’t underestimate the excitation module;the ABB 3BHL000392R0101 is incredibly powerful!It utilizes PID closed-loop control,achieving an excitation regulation accuracy of±0.5%,significantly better than the±2%of standard modules.It can also suppress motor speed fluctuations to within±1 rpm.It also operates stably over a wide voltage range of 220-400V DC,eliminating fluctuations in the workshop’s DC power supply.A power plant’s synchronous generator,previously using a conventional module,suffered from voltage fluctuations due to unstable excitation.After replacing it with the ABB 3BHL000392R0101,the voltage fluctuation dropped from±5%to±1%.This stability is unmatched by any other module,leading many older plants to specifically request the ABB 3BHL000392R0101 when upgrading their motors.

Main Features and Advantages

High-precision excitation:”Motors don’t run out of control”:Conventional excitation modules have an adjustment accuracy of only±2%,resulting in motor speed fluctuations of up to±5rpm.The ABB 3BHL000392R0101 reduces this to±0.5%,reducing speed fluctuations to±1rpm.A metallurgical plant uses it to drive synchronous roller conveyor motors.Previously,conventional modules caused steel conveyors to err,resulting in over 50 tons of steel scrapped monthly.After replacing this module,the deviation rate dropped to 0.1%,saving over 300,000 yuan in material costs annually.

Wide voltage and durability,it’s resistant to voltage fluctuations:Conventional modules only operate within the DC 220V±10%range and lose magnetization at voltages as low as 198V.The ABB 3BHL000392R0101 can handle DC 180-400V and maintain stable excitation even when the workshop’s DC power supply fluctuates to 200V.Previously,a northern factory’s DC panel voltage frequently dropped to 210V in winter,causing conventional modules to trip.After replacing this module,the plant no longer experienced shutdowns due to undervoltage or demagnetization,resulting in an increase in monthly production of over 300 tons and an additional profit of 150,000 yuan.Demagnetization protection,”no motor winding burnout”:It has built-in demagnetization protection.If the excitation current falls below 5%of the rated value,it immediately cuts off the motor power supply,preventing the motor from”idling without magnetization”and burning the windings.Previously,a synchronous pump motor at a chemical plant had a standard module without demagnetization protection.A broken excitation wire went unnoticed,burning the motor windings and costing over 80,000 yuan to repair.After replacing it with the ABB 3BHL000392R0101,it provided two early warnings of demagnetization risk and has never burned the motor again.

Strong compatibility,”can also be used with older motors”:It can be used with both ABB’s own synchronous motors and 100-500kW synchronous motors from other brands,without modifying the motor wiring;simply replace the module.An old power plant used it to upgrade its 1990s-era generator excitation system.Replacing the generator saved over 200,000 yuan simply by replacing the module.It also ran faster than a new system and was operational in just three days.

English Version:

The ABB 3BHL000392R0101 stands out as a high-precision excitation control module designed for medium and high-power synchronous motors.With its advanced PID closed-loop control,it delivers an excitation accuracy of±0.5%,significantly reducing motor speed regulation fluctuation to within±1rpm—far outperforming conventional modules with±2%accuracy.

Equipped with a wide input voltage range(DC 180-400V),it withstands fluctuations in workshop DC power supplies,eliminating downtime caused by undervoltage-induced demagnetization.The built-in demagnetization protection automatically cuts off motor power when excitation current drops below 5%of the rated value,preventing costly stator winding damage from”magnetless idling.”

Compatible with synchronous motors(100-500kW)from ABB and other brands,it supports both manual and automatic control modes,facilitating retrofitting in aging systems without modifying motor wiring.Operating Reliably operating from-10°C to+65°C,it is ideal for harsh industrial environments such as metallurgy plants and power generation facilities.This combination of precision,durability,and compatibility makes the ABB 3BHL000392R0101 an essential component for ensuring stable operation of synchronous motor-driven systems.

Application Areas

Power Plants:”Stable Power Generation”:Synchronous generators in power plants rely on excitation modules to stabilize voltage.Instable excitation can cause output voltage fluctuations,impacting grid power supply.The ABB 3BHL000392R0101 can provide stable excitation in machine rooms operating at temperatures ranging from-10°C to+65°C.One thermal power plant,after implementing it,reduced generator output voltage fluctuations from±5%to±1%,reduced grid assessment penalties from 20,000 yuan per month to zero,and improved power generation efficiency,resulting in an additional 80,000 yuan in monthly profits.

Metallurgical Roller Conveyors:”Precise Conveying”:The synchronous motors in metallurgical plants must operate with precise synchronization.Instable excitation can cause steel conveying to err and cause steel overlap.The ABB 3BHL000392R0101’s±0.5%excitation accuracy reduces roller speed synchronization error to less than 0.1rpm.Using this drive,the steel deviation rate has been reduced from 3%to 0.1%,reducing monthly steel scrap by 80 tons and saving 480,000 yuan in material costs.Roller maintenance has also been reduced from twice a month to once a quarter.

Constant Pressure in Chemical Synchronous Pumps:Synchronous pumps in chemical plants rely on stable excitation to maintain outlet pressure.Excitation fluctuations can cause pressure instability,affecting reactor feed.The ABB 3BHL000392R0101’s PID closed-loop control has reduced pump outlet pressure fluctuations from±4%to±0.8%.Using this drive on a 150kW synchronous pump has stabilized reactor feed,increased product quality from 93%to 99%,reduced monthly defective product production by 60 tons,and saved 360,000 yuan in rework costs.Mine fans save energy:Excitation losses in large synchronous fans in mines account for 8%of total energy consumption.Conventional modules have low excitation efficiency.The ABB 3BHL000392R0101 boasts an excitation efficiency of 95%,10%higher than conventional modules.Using it to drive a 300kW synchronous fan can save 3,000 kWh of electricity per month,or 36,000 yuan in electricity bills per year.Furthermore,the module provides excellent heat dissipation,requiring less frequent cleaning and reducing operation and maintenance costs by 25%.

Selection Guide/Purchasing Recommendations

Choose the ABB 3BHL000392R0101.First,consider the”Motor Parameters”:If your synchronous motor has a power of 100-500kW,an excitation voltage of DC 220-400V,and an excitation current≤50A,such as metallurgical roller table motors or medium-to-large synchronous pumps,this module is perfect.If the motor excitation current exceeds 50A,such as a 600kW generator,it is recommended to choose an ABB excitation module with a higher current.Avoid forcing it,as it may overload and burn out.If the motor power is less than 100kW,this module would be a waste;a lower current model is more cost-effective.

Next,consider the”Operating Conditions”:If you require high-precision control(such as roller table synchronization or pump pressure stability),this module’s±0.5%accuracy is perfect.If the operating condition does not require high accuracy(such as ordinary fans),and you are on a budget,you can consider the basic model.However,in the long run,the stability of this module is more valuable,and avoiding a single failure can save you a lot of money.Never buy”refurbished”parts!The PID control chip and excitation regulation circuitry of the ABB 3BHL000392R0101 are core components.Refurbished parts use outdated chips,resulting in inaccurate adjustment and prone to demagnetization.A customer previously bought a refurbished part and lost over 120,000 yuan after just two months due to unstable excitation,burning out the motor windings.We recommend finding a reliable supplier,such as Shenzhen Changxin[www.cnplcdcs.com].We offer genuine,original parts,and you can check the serial number on every unit for peace of mind.

FAQ

Q:Can the ABB 3BHL000392R0101 be used with other brands of synchronous motors?

A:Definitely!As long as the motor excitation voltage is DC 220-400V and the excitation current is≤50A,it can be used with any Siemens,Mitsubishi,or domestic synchronous motor.A chemical plant previously used it to drive a domestic 200kW synchronous pump.Wiring was done according to the manual,and it worked the first time.Excitation is very stable,with no compatibility issues.

Q:The excitation current fluctuates significantly during module operation.What’s going on?

A:First check the input voltage!If the DC input voltage fluctuates by more than±10%,the excitation current will fluctuate accordingly.First,add a voltage stabilizer to the DC panel.If the voltage is normal,check the PID parameters.Under normal operating conditions,set the proportional(P)value to 5-8 seconds and the integral(I)value to 10-20 seconds.A previous customer had their PID parameters incorrectly set,resulting in current fluctuations of±3%.Adjusting the parameters reduced the fluctuations to±0.5%.

Q:The module reports a”loss of excitation”fault.What should I do?

A:First shut down the machine and check the excitation circuit!Either the excitation wire is broken or has poor contact.Use a multimeter to check for continuity;if broken,reconnect it.Alternatively,the motor excitation winding may be short-circuited.Measure the winding resistance.If shorted,repair the motor.Alternatively,the module parameters may be incorrect;the excitation current threshold may be too high.Lowering it to 5%of the rated value may resolve the issue.A customer previously reported a false demagnetization error due to parameter settings errors,but adjusting the settings resolved the issue.

Q:Can two ABB 3BHL000392R0101s be connected in parallel to excite a single motor?

A:Yes!However,you must use ABB’s dedicated excitation paralleling board and adjust the module parameters to evenly share the current between the two modules.Otherwise,one module will be overloaded and the other idle.A power plant uses two modules in parallel to excite a 600kW generator,and the current sharing error is less than 2%.They have been operating without any issues for two years.They are particularly suitable for motors with excitation currents of 50-100A.

Customer Case Study/Successful Application Analysis

A metallurgical plant in East China previously used conventional excitation modules to drive its 250kW synchronous roller conveyor motors.These modules faced numerous problems:In winter,when the DC panel voltage dropped to 210V,the modules would undervoltage and lose magnetism,resulting in three shutdowns per month and losses exceeding 30,000 RMB each time.In summer,with workshop temperatures reaching 60°C,the modules would trigger overtemperature protection,causing a module burnout once,requiring a five-day repair and costing over 150,000 RMB.Furthermore,poor excitation accuracy caused steel conveying to deviate,resulting in 60 tons of steel scrapped each month and losses exceeding 360,000 RMB.

Later,they switched to the ABB 3BHL000392R0101.Its wide voltage adaptability ensured stable excitation even at 210V,eliminating winter shutdowns due to undervoltage.The plant also continued to operate at temperatures as high as 60°C without further warnings.