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　　3BHE034913R0001 Other Names:

　　Voltage Control Unit 3BHE034913R0001 

　　3BHE034913R0001 Current Control Unit

　　Function of the Braking Resistor Unit: In the PCS6000 system, the braking resistor unit 3BHE034913R0001 is primarily used to absorb regenerative energy generated during motor deceleration or load shedding. It converts electrical energy into heat through resistor heating, preventing excessive DC bus voltage from damaging the inverter or power grid. Typical applications include cranes, elevators, centrifuges, and other equipment requiring rapid braking.

　　System Relevance: As an ABB medium- and high-voltage inverter system, the PCS6000's braking resistor unit must work in conjunction with the inverter and brake unit, sharing regenerative energy through the DC bus or dissipating it through an external braking resistor.

　　Key Technical Parameters:

　　Resistance Value and Power Capacity: For example, the SAFUR125F500 model has a resistance of 500Ω and a rated power of 3.4kW. This resistor must match the conduction threshold of the inverter's brake unit (triggered when the DC bus voltage exceeds 110%-120%).

　　Temperature Resistance and Heat Dissipation: The resistor surface temperature must be ≤200°C. Use a corrugated resistor or aluminum alloy resistor, installed independently in a well-ventilated area. The wire must be heat-resistant and ≤2m long to minimize losses.

　　Braking Cycle and Energy Capacity: For a 30-minute braking cycle, the allowable continuous braking power is 10% of the maximum power. For a 3-minute cycle, the braking time is 40 seconds, and the allowable power is 37% of the maximum power.

　　It is primarily used in high-power industrial applications (such as wind turbines, mine hoists, and port cranes). Its core function is to dissipate energy generated by motor regenerative braking, preventing DC bus voltage from overshooting and protecting the inverter and system.

　　PCS6000 system: ABB's medium-voltage power conversion system supports bidirectional power flow (four-quadrant operation) with a power range of 4-120 MVA, suitable for high-power industrial drives and renewable energy grid integration. The brake resistor unit is a key subsystem, handling rapid braking or energy regeneration scenarios.

　　Resistor parameters: They must be calculated based on motor power, braking torque, and deceleration time. For example, the brake resistor value is typically estimated using the formula R=PU2 (U is the brake unit's operating voltage, and P is the braking power). The power capacity must take into account continuous braking (e.g., for more than 30 seconds) or short-term overload (e.g., 7 times the rated power for 10 seconds).

　　Installation requirements:

　　It must be located externally to the inverter module, ensuring adequate heat dissipation clearance (e.g., an IP21 metal housing or IP00 structure). The cable must be made of high-temperature-resistant material (such as cross-linked polyethylene insulation) and should be no longer than 10 meters to avoid electromagnetic interference.

　　It must be equipped with a thermal switch (normally closed at 120°C) and a cooling fan (activated at 65°C) to prevent overheating damage.

　　Compatibility: It must match the PCS6000 system's DC bus voltage (e.g., 600V/1200V) and be compatible with a braking unit (such as an external high-power transistor module).

　　System Application Scenarios and Advantages

　　Typical Scenarios: In applications requiring rapid braking, such as wind turbines, mine hoists, and port cranes, braking resistor units can absorb regenerative energy fed back from the motor and prevent DC bus overvoltage.

　　Energy Saving and Stability: By sharing the DC bus, multiple inverters can share braking resistors, achieving energy synergy. Combined with an energy regeneration device, excess energy can be fed back to the grid, improving system efficiency.

　　Protection Mechanism: The braking unit monitors the bus voltage through a voltage sampling circuit and dynamically switches the braking resistor on and off, ensuring safe operation in the event of a fault or overload.

　　Energy Efficiency Optimization: By configuring an energy regeneration device (such as a grid-connected inverter), the energy consumed by the braking resistor can be fed back to the grid, improving system energy efficiency (typical energy savings of 10%-30%).

　　Installation and Maintenance Specifications

　　Installation Requirements:

　　Location Selection: Prefer a well-ventilated indoor space away from humid/corrosive atmospheres. Allow ample space for operation and maintenance, and avoid contact with flammable materials.

　　Security and Wiring: Secure the distribution cabinet with screws or standard fasteners. Wire accurately according to the electrical drawings to ensure tight and reliable connections to avoid loose contacts or short circuits.

　　Safety Precautions: During installation, power must be disconnected, appropriate tools must be used, and electrical safety regulations must be followed. Fast-acting fuses must be installed to protect the capacitor unit. If multiple inverters share a common DC bus, electrical isolation must be achieved using interlocking contactors.

　　Maintenance Key Points:

　　Regular Inspection: Monitor the resistor surface temperature (≤200°C) and clean any accumulated dust to maintain heat dissipation efficiency. Check for DC bus voltage fluctuations. If the braking unit is frequently triggered, the resistor capacity or system design should be evaluated for appropriateness.

　　Troubleshooting: Check resistor value deviation (normal within ±5%), brake unit trigger voltage setting (110%-120% of the DC bus rated voltage), cooling fan/temperature sensor function, and troubleshoot open/short circuit, IGBT damage, and other faults.

　　Energy Efficiency Optimization and Industry Applications

　　Energy Efficiency Improvement Solutions:

　　Energy Regeneration Device: Configure a grid-connected inverter to feed braking energy back to the grid, achieving a typical energy saving of 10%-30%.

　　Hardware Upgrade: Use SiC/GaN semiconductor materials to improve the power module's power density and efficiency, and optimize the liquid cooling system to meet the heat dissipation requirements of high power density.

　　Industry Application Examples:

　　Steel Mill System: The PCS6000 drive motor frequently starts and stops, and the brake resistor unit absorbs the regenerative energy from roller deceleration, ensuring system stability.

　　Elevator/Centrifuge: In rapid braking scenarios, the brake resistor unit effectively suppresses DC bus voltage fluctuations, extending equipment life.

　　Potential Problems and Solutions

　　Common Faults: Braking resistor overheating, open circuit, or short circuit; brake unit IGBT damage; abnormal DC bus voltage fluctuations.

　　Troubleshooting Directions:

　　Check whether the resistor value deviates from the nominal value (±5% is normal);

　　Verify whether the braking unit trigger voltage setting is appropriate (usually 110%-120% of the DC bus rated voltage);

　　Check whether the cooling fan, temperature sensor, and overcurrent protection device are functioning properly.

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