ABB 1010 Generator Control Unit | Automatic Voltage Regulator (AVR)

Description

Application Scenarios:

In a hospital, when the main utility grid fails, backup generators must start automatically, synchronize to the correct voltage and frequency, accept the electrical load, and maintain perfect power quality for life-saving equipment—all within seconds. The ABB UNITROL 1010​ is engineered to orchestrate this critical sequence. It continuously monitors the generator’s output. As the diesel engine starts, the UNITROL 1010’s AVR function precisely excites the generator field to build up voltage to the setpoint. It then compares the generator’s voltage and frequency with the mains (or other generators in a parallel system) and provides fine adjustment signals to the engine governor and its own excitation system to achieve perfect synchronization. Once synchronized, it smoothly transfers the load and continuously regulates voltage despite fluctuating hospital loads, such as MRI machines cycling. It solves the core challenges of automatic, reliable, and precise generator control and protection​ in mission-critical applications.

Parameter:

Technical Principles and Innovative Values:

Innovation Point 1: Integrated Multi-Loop Control for Superior Stability.​ The UNITROL 1010​ goes beyond simple voltage regulation. It implements advanced control algorithms that manage the complex interaction between the generator’s excitation system (its field) and the prime mover’s speed governor. It provides not only voltage control (AVR mode) but also power factor (Var/PF control) and frequency/active power control (through isochronous or droop characteristics). This integrated control ensures exceptional stability during load transients, such as starting large motors, preventing engine stalling or voltage collapses.

Innovation Point 2: Advanced Synchronization and Seamless Load Transfer.​ The unit features a precise auto-synchronization function. It measures the voltage, frequency, and phase angle difference between the generator and the busbar (or mains). It then sends “raise/lower” signals to the engine governor and adjusts the generator voltage internally to achieve near-perfect matching before closing the generator circuit breaker. This prevents damaging mechanical and electrical stresses on the generator and prime mover, enabling smooth, bumpless transfers.

Innovation Point 3: Comprehensive Embedded Protection and Diagnostics.​ The UNITROL 1010​ incorporates a full suite of protective relays (over/under voltage, over/under frequency, overcurrent, reverse power, etc.), eliminating the need for many external discrete protection devices. It continuously performs self-diagnostics on its hardware and software. All events, alarms, and measurements are logged, providing invaluable data for troubleshooting, preventive maintenance, and analyzing power quality events.

Application Cases and Industry Value:

Case Study: Data Center Parallel Generator System.

A large data center required four 2MW diesel generators to operate in parallel to support its critical load during utility outages. The challenge was to ensure they shared the total load proportionally and responded instantly to load changes without instability. Each generator was equipped with an ABB UNITROL 1010​ controller. The units were configured for isochronous load sharing with digital cross-communication. During a simulated blackout, all four units started, synchronized to each other, and accepted the data center load, with each UNITROL 1010​ automatically adjusting its generator’s output to maintain a 25% share. The facility manager stated: “The UNITROL 1010​ system made parallel operation seem effortless. The load sharing is so precise we see no hunting or circulating currents. Its built-in protection gave us confidence, and the remote monitoring via Modbus integrated perfectly into our building management system, providing complete visibility.”

Case Study: Island Mode Microgrid for Remote Mining Site.

A remote mining operation powered by multiple generators running in island mode (no connection to a main grid) suffered from frequency and voltage instability whenever large crushers started, causing production delays. They retrofitted their existing generators with ABB UNITROL 1010​ controllers. The units’ fast-acting AVR and robust engine speed control via the droop function provided immediate response to load changes. The ability to set different droop characteristics allowed them to prioritize base load on the most efficient generator. The chief engineer reported: “Installing the UNITROL 1010​ was a turning point. Voltage and frequency dips during large motor starts were reduced by over 70%. The system is now stable, which has increased the lifespan of our electrical equipment and eliminated downtime caused by protection trips. The payback in reliability alone was worth the investment.”

Related Product Combination Solutions:

ABB CP600 / CP-Series Control Panels:​ Advanced graphical control panels that provide the human-machine interface (HMI), system logic, and data logging for gensets controlled by the UNITROL 1010. creating a complete control solution.

ABB UG Governor Actuator:​ An electric actuator designed to interface with diesel engine mechanical governors; the UNITROL 1010​ can send speed control signals to this actuator for precise frequency/load control.

ABB DSTU/DTU Transfer Switch Controller:​ An automatic transfer switch controller; the UNITROL 1010​ can work in conjunction with it for controlling generator start/stop and synchronization during mains failure.

ABB REL 5xx / REF 6xx Protection Relays:​ While the UNITROL 1010​ has basic protection, for very high-value assets, these dedicated protection relays can provide backup or more advanced protection schemes.

ABB Ability™ Generator Insights:​ A cloud-based monitoring and analytics platform; data from the UNITROL 1010​ (via a gateway) can be fed into this platform for predictive maintenance and performance optimization.

ABB A155 Auxiliary Power Supply:​ A reliable power supply unit that can provide a stable DC source for the UNITROL 1010​ and other control components.

Synchronizing and Load Sharing Lines:​ The cabling kits used to interconnect multiple UNITROL 1010​ units for paralleling generators, ensuring proportional load sharing.

Installation, Maintenance, and Full-Cycle Support:

Installation of the ABB UNITROL 1010​ should be performed by qualified electrical personnel. It is typically panel-mounted. Key connections include: the generator voltage and current transformer (VT/CT) inputs for measurement, the excitation output to the generator field, the speed signal input from a magnetic pickup on the flywheel, communication lines for load sharing and SCADA, and control wiring to the circuit breaker and engine start system. Configuration is performed via the front-keypad and display or more efficiently using ABB’s Toolkit​ configuration software on a PC.

Routine maintenance involves verifying measurement accuracy (VT/CT ratios) and checking calibration. The unit’s extensive event log and data recorder are valuable tools for health monitoring. Common issues include loss of synchronization (check VT/CT connections and speed sensor) or unstable voltage (check AVR parameters and stability settings). Firmware updates are released periodically and should be applied as recommended. We supply the genuine ABB UNITROL 1010​ unit. Our technical support can assist with wiring diagrams, initial configuration, and integration guidance to ensure your generator system delivers reliable and stable power.

Ensure your backup or prime power generation is under precise, reliable control. Contact us for the genuine ABB UNITROL 1010 and expert support for your generator control application.