Description

The ABB UNITROL1010 3BHE035301R0001​is a state-of-the-art digital excitation system controller,representing the core intelligence within ABB’s UNITROL 1000 series for precise voltage and reactive power control of synchronous generators.This advanced regulator transforms generator terminal conditions into precise firing commands for thyristor bridges,dynamically managing the magnetic field of the rotor to ensure stable,efficient,and grid-code-compliant power generation.

Application Scenarios

In a large hydroelectric power plant,the generator’s output must respond instantly to grid dispatcher commands for voltage support and frequency regulation.During a sudden grid disturbance,such as a nearby fault causing voltage depression,the UNITROL1010​controller springs into action.It continuously samples generator terminal voltage and current.Within milliseconds,its advanced control algorithms calculate the exact increase in field current required to inject reactive power(VARs)into the grid,supporting voltage recovery.Simultaneously,its Power System Stabilizer(PSS)function damps electromechanical oscillations that could otherwise cause the generator—and potentially the entire plant—to swing uncontrollably.For the plant operator,the 3BHE035301R0001​is the guardian of grid stability and generator safety.Its failure could lead to undamped oscillations,loss of voltage control,generator pole slipping,and a forced outage,translating to massive revenue loss and potential grid instability.This controller directly addresses the critical pain points of maintaining grid compliance and protecting multimillion-dollar generating assets.

Parameter

Main Parameters

Value/Description

Product Model​

UNITROL1010 3BHE035301R0001​

Manufacturer​

ABB

Product Category​

Digital Excitation System/Automatic Voltage Regulator(AVR)

Control Functions​

Automatic Voltage Regulation(AVR),Field Current Regulation(FCR),Power System Stabilizer(PSS),Limiters(U/F,V/Hz,Stator/Rotor Current)Comprehensive suite for full generator control and protection.

Input Signals​

Generator VT(Voltage),CT(Current),Field Voltage&Current,Breaker Status,Setpoints

Output Signals​

Firing Pulses to Thyristor Bridges,Alarms,Trips,Analog Outputs for SCADA

Regulation Accuracy​

Typically better than±0.5%of setpoint Ensures precise voltage control for grid quality.

Response Time​

<20 ms for a step change in reference voltage Critical for fast grid support functions.

Communication Interfaces​

Multiple serial ports(RS485/232),Ethernet(Modbus TCP/IP,IEC 61850 optional)Enables integration with plant DCS/SCADA and remote control.

Display&Interface​

Graphical LCD with keypad for local operation and configuration

Operating Temperature​

0°C to+55°C(for control cubicle installation)

Power Supply​

Dual-redundant 110/220 VAC or 125/250 VDC High availability design.

Standards Compliance​

IEEE 421.5,IEC 60255,Grid Connection Codes

Technical Principles and Innovative Values

Innovation Point 1:Adaptive,Multi-Loop Control Architecture.The UNITROL1010​employs a sophisticated,adaptive control structure that goes beyond simple PID loops.Its AVR algorithm can automatically adjust its parameters based on generator operating point(e.g.,lagging vs.leading power factor)to maintain optimal damping and response.The integrated PSS uses a dual-input design(typically power and frequency)to effectively damp oscillations across a wide range of system conditions,a feature that is manually tuned and fixed in lesser regulators.

Innovation Point 2:Comprehensive Model-Based Limiters and Protections.Instead of simple high/low limits,the controller implements intelligent,model-based limiters.For example,its Under-Frequency(U/F)or Volt-per-Hertz(V/Hz)limiter dynamically calculates a safe maximum field current based on real-time frequency to prevent generator transformer core saturation during slow speed ramps or system under-frequency events.This proactive protection prevents damage while maximizing the generator’s available capability during disturbances.

Innovation Point 3:True Dual-Channel Redundancy with Bumpless Transfer.The system is designed around a principle of functional redundancy.It can be configured with two independent UNITROL1010​regulator channels(Auto and Standby).Each channel has its own power supply and processes signals from independent sensor sets.The active channel controls the thyristors.If a fault is self-detected or a manual switch is initiated,the transfer to the standby channel is truly bumpless—occurring within a single firing cycle without any disturbance to the generator’s terminal voltage.This architecture delivers availability figures exceeding 99.99%.

Application Cases and Industry Value

Case Study:Grid Code Compliance for a Wind Farm Synchronous Condenser.A large wind farm required a new synchronous condenser(a rotating machine that provides only reactive power)to meet stringent new grid codes mandating fault ride-through and dynamic voltage support.ABB’s UNITROL1010​was selected as the excitation system.During commissioning,its advanced PSS was finely tuned to damp specific subsynchronous resonance modes identified in the grid study.

During its first major grid test—a distant transmission line fault causing a 30%voltage dip for 500ms—the UNITROL1010​demonstrated its value.Its fast AVR response pushed the condenser to its capacitive current limit within 40ms,injecting maximum reactive power to support the local voltage.More importantly,its PSS successfully suppressed subsequent 1.2 Hz power oscillations that were excited by the fault,which the old excitation system on a neighboring machine failed to do.The grid operator’s report confirmed the wind farm met all dynamic performance requirements.The owner quantified the benefit not only in avoided non-compliance penalties but also in the increased capacity factor for the wind turbines,as stable voltage allowed them to remain online during the disturbance.The performance of the 3BHE035301R0001​controller was cited as a key differentiator in the project’s success.

Related Product Combination Solutions

UNITROL1020:The enhanced version in the series,often including integrated sequential control for exciter field breaker and de-excitation switch,and more advanced communications.

Thyristor Power Bridges(e.g.,5STP 26N4200):The power stages that convert AC to DC field current,directly fired by the pulses from the UNITROL1010.

Excitation Transformers:Provide the isolated AC supply to the thyristor bridges.Their specifications are closely coordinated with the regulator’s capabilities.

Field Discharge Resistors/Crowbars:Controlled by the UNITROL1010​for safe de-energization of the field during trip events,protecting the rotor insulation.

UNS0880a or similar:The Operator Workstation software(Toolkit).Used for configuring all parameters,real-time monitoring,oscillography,and disturbance recording on the UNITROL1010.

Remote I/O Modules:For distributing measurement signals(VT/CT)or collecting breaker statuses,often communicating with the main regulator over a fieldbus.

Installation,Maintenance,and Full-Cycle Support

Installation involves mounting the UNITROL1010​controller in a protected control cubicle,connecting it to highly accurate,dedicated Voltage Transformer(VT)and Current Transformer(CT)circuits with proper shielding.The firing pulse cables to the thyristor gates must be twisted-pair and routed away from power cables to prevent interference.Commissioning is a critical phase performed with ABB’s Toolkit software,involving steps like sensor calibration,control loop tuning(AVR,PSS),and exhaustive testing of all limiters and protection functions,often using a static frequency converter test set to simulate grid disturbances.

Maintenance is heavily reliant on the controller’s extensive self-diagnostics and logging capabilities.Routine tasks include reviewing event logs and disturbance records(which capture data before,during,and after any alarm),verifying the health of redundant channels,and checking the condition of external components like fans and power supplies.Firmware updates can be applied to add features or address specific issues.Having a complete spare UNITROL1010​controller,pre-loaded with the configuration,is considered best practice for critical units to minimize MTTR(Mean Time To Repair).

We provide holistic support for the ABB UNITROL1010 3BHE035301R0001​throughout its lifecycle.Our services span from initial system design and application engineering to on-site commissioning supervision and comprehensive training for your staff.We offer technical support for troubleshooting,performance optimization,and retrofit projects.We supply genuine ABB parts,including controllers,power modules,and kits,and can manage your critical spares inventory.Our goal is to be your trusted partner in ensuring the reliability and performance of your critical excitation systems.

Contact us for an excitation system assessment,to discuss a modernization project,or for reliable supply of UNITROL series components and expert support.

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