ABB GRID BREAKER UNIT GBU72 3BHE031197R0001

Overview

ABB GRID BREAKER UNIT PCS6000 (referred to as GBU PCS6000) is a key component of the ABB PCS6000 product family, an intelligent grid-connected circuit breaker unit specifically designed for new energy power generation systems, grid energy storage systems, and the public power grid. It mainly undertakes the functions of connecting, disconnecting, and protecting between the power conversion system and the power grid. It can reliably connect the power channel during normal operation of the system, and quickly cut off the connection when faults (such as overvoltage, short circuit, islanding effect) occur, preventing the fault from spreading to the power grid or damaging power generation/energy storage equipment. It is a "safety guard" to ensure the safe and stable operation of the power system.

Core Functions

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• Grid-connection and Disconnection Control: According to system instructions or grid status, it realizes the rapid connection (grid-connection) or disconnection (disconnection) between new energy power generation systems (such as photovoltaics, wind power), energy storage systems and the power grid. The grid-connection process adopts soft-start technology, which avoids impact on the power grid by gradually adjusting the closing phase and current; during disconnection, it quickly cuts off the current to ensure safe separation between the system and the power grid, with a response time of no more than 50ms, meeting the requirements of the power grid for the rapid response of grid-connection equipment.

• Comprehensive Fault Protection: Equipped with multiple protection mechanisms, including overcurrent protection (action threshold can be set, ranging from 1.2-5 times the rated current), overvoltage/undervoltage protection (voltage threshold can be set according to grid standards, such as ±10% rated voltage), frequency abnormality protection (45-55Hz adjustable), islanding effect protection (detection accuracy up to 2%, response time<200ms) and short-circuit protection, etc. When a grid or system fault is detected, it can trigger a trip within milliseconds to cut off the fault circuit, protecting power generation equipment, energy storage batteries, and grid equipment from damage.

• Status Monitoring and Communication: Built-in high-precision sensors and intelligent monitoring modules can collect real-time operating parameters such as switch status, passing current/voltage, and temperature. It communicates with the PCS6000 monitoring system or the upper-level grid dispatching center through industrial Ethernet (supporting PROFINET and Modbus TCP/IP protocols), uploads status data and fault information, and receives remote control commands (such as remote closing/opening) to realize remote operation and monitoring in unattended scenarios.

• Synchronized Grid-connection Control: Before grid-connection, through the built-in synchronization detection circuit, it compares the phase, frequency, and amplitude of the system output voltage and the grid voltage in real-time. Only when the difference between the two is within the allowable range (phase difference<5°, frequency difference <0.1Hz, voltage difference <5%), closing and grid-connection are allowed, ensuring a smooth and impact-free grid-connection process, and avoiding current impact and equipment damage caused by inconsistent phases.

Technical Parameters

• Rated Parameters: The rated voltage range is AC 690V-10kV (can be customized according to grid requirements), the rated current can reach 1250A, the short-time withstand current (1s) is 31.5kA, and the peak withstand current is 80kA. It can withstand the huge current impact during system short circuits, meeting the capacity requirements of medium and large new energy power stations and energy storage systems.

• Mechanical Performance: The mechanical life is ≥10,000 operations (opening/closing cycles), and the electrical life is ≥3,000 times (under rated current). The operating mechanism adopts spring operating or permanent magnet operating technology, with a closing time<60ms and an opening time <30ms. The action speed is fast, ensuring quick circuit cutoff in case of faults.

• Environmental Adaptability: The operating temperature range is -25℃ to +70℃, and it can operate stably in outdoor substations in cold areas or high-temperature workshops; the relative humidity is 5%-95% (no condensation), with anti-corrosion coating and sealing design, adapting to humid, dusty, or coastal salt spray environments, and the protection level reaches IP54 (outdoor type can reach IP65).

• Physical Specifications: Adopting a modular structure, the size varies according to the rated voltage and current. Taking the 690V/1250A model as an example, the size is approximately 4960 x 1280 x 2460mm, and the weight is about 150kg. It can be installed in standard switch cabinets or outdoor equipment brackets, with fixed or drawer-type installation methods, facilitating maintenance and replacement.

Technical Features

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• High Reliability Design: Core components (such as contacts, operating mechanisms, sensors) are made of wear-resistant and anti-aging industrial-grade materials, and have undergone strict high and low-temperature cycle, vibration, and impact tests to ensure long-term stable operation in harsh environments. At the same time, the operating mechanism adopts an oil-free design, avoiding faults caused by oil leakage of traditional hydraulic mechanisms and reducing maintenance costs.

• Intelligent Collaborative Control: It achieves in-depth collaboration with PCS6000 converters and controllers. During the grid-connection/disconnection process, the converter first adjusts the output to synchronize with the grid, and then the GBU performs the closing operation; in case of a fault, the converter and GBU are linked, the converter stops output first, and then the GBU opens, avoiding arc damage to contacts during opening and extending equipment life.

• Redundant Design: Key control circuits and power supplies adopt redundant configurations. When the main control module or power supply fails, the backup module automatically switches to ensure that protection functions and communication functions are not interrupted, improving system availability and meeting the high reliability requirements of the power grid for key equipment.

• Arc Protection: Built-in arc sensors and fast arc extinguishing devices. When an arc short circuit occurs in the cabinet, it can detect the arc signal within 2ms and trigger a quick opening. At the same time, the arc energy is released through the pressure relief channel to prevent the switch cabinet from exploding and protect the safety of operation and maintenance personnel and equipment.

Application Scenarios

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• Large-scale Photovoltaic Power Plant Grid-connection System: In gigawatt-level photovoltaic power plants, GBU PCS6000 is installed between the AC side of the photovoltaic inverter and the step-up transformer, serving as the "main switch" for the photovoltaic array to connect to the grid. During normal operation, it reliably connects the inverter and the grid to realize power transmission; when the grid has voltage sag, frequency abnormality, or internal faults in the photovoltaic system, it quickly opens and disconnects to prevent the fault from affecting grid stability and protect the inverter and photovoltaic modules.

• Grid-level Energy Storage System: In large-scale lithium battery energy storage power stations, GBU PCS6000 is used to connect the energy storage converter (PCS) and the grid, undertaking the on-off control during the charging and discharging process of the energy storage system. When the grid load is low, it receives dispatching instructions to close, allowing the energy storage system to charge from the grid; during peak load, it closes to release electric energy; if the energy storage battery is overcharged, short-circuited, or the grid fails, it immediately opens to cut off the circuit, protecting the battery pack and grid equipment.

• Wind Farm Collection System: In wind farms, multiple wind turbines are aggregated through collection lines and then connected to the step-up station via GBU PCS6000. It can monitor the current and voltage status of the collection lines. When a wind turbine fails or the line is short-circuited, it quickly opens to isolate the fault area, avoiding affecting the normal operation of other wind turbines, and at the same time cooperates with the wind farm control system to realize the orderly grid-connection and shutdown of wind turbines.

• Microgrid System: In a microgrid including distributed generation (photovoltaics, diesel generators), energy storage, and loads, GBU PCS6000 serves as the connection point between the microgrid and the main grid, realizing the switching between "grid-connected operation" and "island operation" modes. When the main grid is normal, it connects the microgrid and the main grid to realize power complementation; when the main grid fails, it quickly opens to make the microgrid switch to island mode for independent operation, ensuring uninterrupted power supply for important loads (such as hospitals, data centers).

Summary