The ABB UNITROL1020 3BHE030579R0003 is a state-of-the-art, digital automatic voltage regulator (AVR) and excitation controller, a core component of ABB’s renowned UNITROL® 1000 series. Engineered for synchronous generators, this advanced controller is responsible for the precise regulation of generator terminal voltage and reactive power, ensuring stable and efficient power generation under all operating conditions. The ABB UNITROL1020 achieves this by continuously monitoring the generator’s electrical parameters (voltage, current, frequency, power factor) and dynamically adjusting the field current supplied to the generator’s rotor via a thyristor-based power unit. Its primary mission is to maintain a constant generator terminal voltage despite fluctuations in load, prime mover speed, or system disturbances, thereby ensuring power quality and grid stability. The suffix 3BHE030579R0003denotes a specific hardware configuration, including I/O options, communication interfaces, and power rating tailored to the application.
As a fully digital system, the ABB UNITROL1020 transcends the role of a simple regulator. It integrates comprehensive protection functions for the generator and excitation system, advanced control loops for enhanced stability (Power System Stabilizer — PSS), and seamless communication capabilities for integration into plant DCS/SCADA systems. It is designed for a wide range of synchronous machines, from small industrial generators to large utility-scale units. For operators of power plants, industrial co-generation facilities, and marine propulsion systems, the ABB UNITROL1020 provides the intelligence and reliability needed for optimal generator performance, contributing to grid support, black start capability, and protection of valuable generating assets.
Technical Specifications
Parameter Name
Parameter Value
Product Model
ABB UNITROL1020 3BHE030579R0003
Manufacturer
ABB
Product Series
UNITROL® 1000 Series
Product Type
Digital Automatic Voltage Regulator (AVR) & Excitation Controller
Control Loops
Automatic Voltage Regulation (AVR), Field Current Regulation (FCR), Reactive Power/Power Factor Control, V/Hz Limiting
Power System Stabilizer (PSS)
Integrated, configurable PSS to damp electromechanical oscillations and enhance grid stability
Input Signals
Generator terminal voltage (VT), Generator current (CT), Field voltage/current, Breaker status, etc.
Output Control
Controls a thyristor bridge (power unit) to provide controlled DC field current to the generator rotor.
Excitation Power Source
Can be configured for shunt (potential transformer), compound, or brushless exciter supply.
Protection Functions
Over/Under Excitation (OEL/UEL), Volts per Hertz (V/Hz), Field Overcurrent, Loss of Excitation (40G), Diode Failure (for brushless), etc.
Communication Interfaces
Multiple serial (RS485) and Ethernet ports. Supports Modbus RTU/TCP, IEC 60870-5-103/104, DNP3, and often IEC 61850.
Human-Machine Interface
Color graphical display with touch screen or keypad for local operation and monitoring.
Power Supply
Dual-redundant DC or AC power supplies (e.g., 24-48 V DC, 110/230 V AC).
Operating Temperature
0°C to +60°C (for controller cabinet).
Certifications
Complies with major grid codes, IEEE 421.5, IEC 60255, UL, CE.
Key Features and Advantages
ABB UNITROL1020 3BHE030579R0003 is distinguished by its advanced control algorithms and exceptional grid support capabilities. Its core advantage is the use of high-performance digital signal processors to execute precise and fast control loops, ensuring excellent voltage regulation accuracy (typically within ±0.5%) and dynamic response to load changes. The integrated, adaptive Power System Stabilizer (PSS) is a critical feature for utility generators, actively damping low-frequency power oscillations to improve the stability limits of the entire power system.
UNITROL-1020-UNS0119A-Z,V1-3BHE030579R0003
Superior protection and diagnostic intelligence are integral to its design. The controller incorporates a comprehensive set of protection functions specifically for synchronous machines, such as Loss of Excitation (40G) and Over/Under Excitation Limiters (OEL/UEL), which protect the generator from damage and prevent it from exceeding its capability curve. Extensive built-in diagnostics continuously monitor the health of the controller, its I/O, and the connected thyristor power unit, enabling predictive maintenance and rapid fault identification. Clear event logging and oscillographic recording of disturbances provide invaluable data for post-event analysis.
Unparalleled flexibility and connectivity make it a future-proof investment. The ABB UNITROL1020 supports a wide array of control modes (AVR, FCR, Var/PF control) and can be easily configured for different excitation topologies (static, brushless). Its support for multiple industry-standard communication protocols, including modern standards like IEC 61850, allows for seamless integration into any plant control system (DCS, SCADA) and facilitates remote monitoring, control, and asset management. The user-friendly local HMI simplifies commissioning and daily operations. For generator owners, this controller delivers not only rock-solid voltage control but also the tools needed for optimal generator performance, compliance with stringent grid codes, and enhanced asset management throughout the generator’s lifecycle.
Application Areas
The ABB UNITROL1020 3BHE030579R0003 is the excitation controller of choice for a vast range of synchronous generators across the power generation landscape.
In utility-scale power plants (thermal, hydro, nuclear, gas turbine), it is deployed as the primary AVR for the main generator, ensuring stable voltage output for the grid and providing essential grid support services like VAR control and oscillation damping via its PSS. Within industrial power generation and co-generation facilities (paper mills, chemical plants, refineries), it controls generators that supply both process power and export surplus to the grid, requiring precise voltage and reactive power management.
For renewable energy integration, it is used in synchronous condensers and certain types of biomass or biogas plants that utilize synchronous generators. In the marine sector, it controls the excitation of synchronous generators on ships and offshore platforms for the vessel’s electrical network. It is also critical for diesel and gas engine-driven generators in standby, prime power, and island grid applications, where its fast response is key to maintaining voltage stability during load steps. Essentially, any application involving a synchronous generator that requires reliable, precise, and intelligent voltage and reactive power control is a prime application for the ABB UNITROL1020.
Related Products
ABB UNITROL1020 (other order codes): Variants with different I/O counts, communication options, or specific certifications.
ABB Thyristor Power Unit (e.g., UNITROL® PU): The controlled rectifier bridge that supplies the DC field current, commanded by the UNITROL1020 controller.
ABB Excitation Transformer: The transformer that provides the AC supply to the thyristor power unit.
ABB Field Circuit Breaker / Field Discharge Resistor: Protection and switching devices in the generator field circuit.
ABB Generator Protection Relay (e.g., REG670): A dedicated protection relay that works in conjunction with the AVR for comprehensive generator protection.
ABB Ability™ Generator Insights or Optimization Products: Digital solutions for advanced monitoring and performance optimization of the generator-exciter set.
ABB ToolKit SPAC (Software for Plant Automation Control): The PC-based engineering tool used for configuration, commissioning, and monitoring of UNITROL controllers.
Voltage & Current Transformers (VTs/CTs): The instrument transformers that provide scaled measurement signals to the AVR.
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