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CCA2 | ABB | medium voltage full power converter | 3BHE057277E16 | CCA2

It supports energy feedback (such as wind power braking energy and subway regenerative braking energy fed back to the grid), achieving full coverage of power generation and consumption scenarios with a conversion efficiency of >98% (full load). It uses IGCT (integrated gate-commutated thyristor) technology to reduce losses, and the output total harmonic distortion (THD) rate is <3%, meeting the IEEE 519 standard and reducing pollution to the power grid. It is suitable for scenarios with strict requirements on power quality, efficiency and space utilization, such as offshore wind power and urban rail transit energy feedback.

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  CCA2 3BHE057277E16 Other Names:

  PCS6000 System Medium-Voltage Wind Turbine Converter CCA2 3BHE057277E16

  PCS6000 System Static Var Compensator CCA2 3BHE057277E16

  PCS6000 System Power Distribution Panel CCA2 3BHE057277E16

  ABB's PCS6000 is a modular medium-voltage power electronics conversion platform. CCA2 3BHE057277E16 is designed specifically for high-power industrial scenarios and renewable energy grid integration.

  It offers the following core capabilities:

  Power Range and Voltage Levels

  The PCS6000 system adopts a modular design, with a single module power range of 4-120 MVA and support for direct access to medium-voltage grids from 3.3 kV to 35 kV. The CCA2 3BHE057277E16 is a high-power module (e.g., over 100 MVA) suitable for medium-voltage grid-connected scenarios such as offshore wind power and large-scale photovoltaic power plants.
  Four-quadrant bidirectional power flow

  Supports energy regeneration (e.g., wind turbine braking energy and subway regenerative braking energy fed back to the grid), achieving full coverage of power generation and consumption scenarios.

  Wide power range and voltage levels

  Single module power: 4-120 MVA (expandable to 200+ MW)

  Input voltage: 3.3 kV-35 kV (customizable), suitable for direct connection to the medium-voltage grid without the need for additional step-up/step-down equipment.

  High efficiency and low harmonics

  Conversion efficiency exceeds 98% (full load), utilizing IGCT (Integrated Gate Commutated Thyristor) technology to reduce losses.

  Output total harmonic distortion (THD) is less than 3%, meeting IEEE 519 standards and reducing grid pollution.

  Topology and Efficiency

  The system is based on modular multilevel converter (MMC) technology, supporting four-quadrant operation and achieving ≥98% efficiency (at full load). The CCA2 3BHE057277E16 continues this architecture, using IGCTs (integrated gate-commutated thyristors) to achieve low harmonic output (THD<3%), complying with IEEE 519 standards.

  Cooling Methods and Redundancy

  The PCS6000 offers both air and water cooling modes and supports hot-swappable replacement of faulty modules. The CCA2 3BHE057277E16 utilizes a closed-loop water cooling system with redundant cooling pumps to ensure stability in offshore and high-temperature environments.
  Technical Architecture and Key Features

  Modular Multilevel Converter (MMC) Topology

  Flexible expansion is achieved through cascading standard power modules, supporting a "building block" configuration to meet varying power requirements.

  The multilevel output waveform is nearly sinusoidal, with extremely low dv/dt, protecting motor insulation and extending equipment life.

  Dual-Mode Cooling System

  Supports air-cooled/water-cooled closed-loop design with automatic switching between redundant cooling pumps, ensuring stable operation in high-temperature environments and extending maintenance intervals.

  Intelligent Control and Protection

  Core controller: ABB AC800PEC PLC, integrated with sensorless algorithms, achieves precise torque control and fast dynamic response.

  Protection functions: Overload, short circuit, overvoltage, and grid fault ride-through (LVRT/FVRT) ensure system safety under extreme operating conditions.

  Functional Feature Analysis

  Grid Synchronization and Protection

  Similar to the GBU72 control cabinet, the CCA2 3BHE057277E16 integrates grid synchronization detection, circuit breaker drive control, and fault isolation capabilities. It supports low voltage ride-through (LVRT) and grid fault ride-through, ensuring the safety of renewable energy grid integration.

  Dynamic Reactive Power Compensation

  The PCS6000 system dynamically compensates reactive power by adjusting the output voltage phase (adjustable from 0.95 leading to 0.95 lagging power factor), improving grid voltage stability. Modular Scalability

  The system supports a "building block" architecture, enabling flexible configuration from 5 MW to over 200 MW by adding power modules. The CCA2 3BHE057277E16, a high-power density module, simplifies the expansion process for large projects

  Technical Advantages:

  The PCS6000 system features high efficiency (>98%), low harmonics (THD<3%), and a modular design. The CCA2 3BHE057277E16, as a high-power model, can significantly reduce the Levelized Cost of Electricity (LCOE) of large-scale renewable energy projects.

  Typical Application Scenarios

  Renewable Energy Grid Integration

  Wind Farms: Serves as a full-power converter, connecting low-speed permanent magnet generators to the grid to achieve soft start, reactive power compensation, and low-voltage ride-through.

  Photovoltaic Power Plants: Supports high-voltage DC inverters, improving grid efficiency and power quality.

  Industrial Drive and Speed Control

  Applied to large motor drives (such as mine hoists and ball mills) in industries such as steel rolling, mining, and cement, achieving energy savings and consumption reduction through variable frequency speed control.

  Grid Support and Energy Storage

  Dynamic VAR Compensation (SVC Light®): Improves grid voltage stability and power factor.

  Energy Storage System Interface: As a high-voltage grid-connected energy storage converter, it enables temporal and spatial shifting of electrical energy.

  Model CCA2 3BHE057277E16 Differentiating Advantages

  High Power Density and Compact Design

  Integrated voltage limiting unit, pre-charge unit, and water cooling system reduce footprint, making it suitable for deployment inside towers or in confined spaces.

  Fuse-Free Design

  In offshore wind power scenarios, remote restart is possible after troubleshooting, eliminating the need for on-site fuse replacement and reducing O&M costs.

  Full-Speed Range Testing Capabilities

  Supports full-speed testing of generator motoring conditions in U/F mode, efficiently verifying component reliability before shipment.

  Industry Evaluation and Market Position

  The ABB PCS6000 series, with its high reliability, modular design, and full power coverage, holds a leading position in the global wind power, industrial drives, and power grid sectors. The high-end model, CCA2 3BHE057277E16, is particularly suitable for scenarios requiring stringent power quality, efficiency, and space utilization, such as offshore wind power and urban rail transit energy regeneration.


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