ABB PCS100 SFC Static Frequency Converter
Technical Catalogue
Introduction
The PCS100 Static Frequency Converter (SFC) addresses the challenge of converting power between different frequencies, such as 50Hz and 60Hz, and can also convert voltage levels. It utilizes static technology, meaning no large moving parts, for reliable operation. The SFC is highly configurable, with options ranging from 125kVA up to 2MVA, and larger systems can be achieved through paralleling units. It incorporates industry-standard control interfaces for seamless integration into existing installations. This catalogue provides guidance for product selection and system requirements.
The Company
ABB is a global leader in power electronics and power protection equipment. As part of ABB, the company offers extensive application expertise, service, and support worldwide. Commitment to teamwork, high-quality manufacturing, advanced technology, and unparalleled service are core values. Product quality and performance are a result of over 100 years of experience and continuous innovation. The products are manufactured in an ISO 9001 accredited facility.
For more information, further publications for the PCS100 SFC are available for free download from www.abb.com/pcs100-power-converters.
System Overview
The PCS100 SFC enables the connection of 60Hz equipment to a 50Hz supply network and vice versa. It can also convert the supply voltage to meet load requirements. Key technical features include advanced IGBT technology, compact design, modularity, low maintenance, high reliability, precise output frequency generation, bi-directional power flow, and remote monitoring via Ethernet and Modbus-TCP/IP protocols.
The system converts input AC power to a DC link via a sine-wave rectifier and then to a clean, full sine-wave AC output at the desired frequency and voltage using a sine-wave inverter. An isolation transformer is essential for the SFC system and can be placed at the input or output. The PCS100 SFC uses state-of-the-art power electronic modules. The primary user interface is an intuitive 8.4" touch screen Graphical Display Module (GDM). System monitoring can be achieved through PLC connection (digital/analog I/O) or SCADA systems via TCP/IP Ethernet.
Image Description: A large, multi-cabinet unit labeled 'PCS100-03-05F-LH+T500' is shown, representing the PCS100 SFC system.
Sub Assemblies
A SFC system comprises the following sub-assemblies:
- Input circuit protection (model dependent)
- Rectifier Power Modules
- Inverter Power Modules
- Isolation transformer (sold separately)
Diagram Description: A block diagram illustrates the SFC system. Input utility power (50/60 Hz) goes through optional input circuit breakers to the PCS100 SFC, which contains a rectifier and inverter. An isolation transformer is shown after the inverter, before the output to the load. The output load voltage is also shown. Legend indicates Utility Voltage and Load Voltage.
Rectifiers & Inverters
The PCS100 SFC utilizes pairs of rectifier and inverter power modules. Rectifier modules convert incoming AC voltage to a regulated DC voltage, which is then supplied to the inverter modules to generate the AC output at a different frequency. The system can use one to sixteen replaceable ABB PCS100 module pairs. These modules are highly integrated and can operate independently, allowing continued operation at reduced capacity if a module fails. A master controller manages all power modules and communication.
Image Description: A photograph shows a single ABB PCS100 SFC module.
Input Circuit Breakers
For SFC systems requiring multiple enclosures, circuit breakers are fitted to the input to protect internal cabling. Overload protection is handled electronically by the power electronics control. One circuit breaker is fitted per full-size converter cabinet. Smaller SFC units (up to four module pairs) do not include input breakers; suitable protection must be installed in the supply. Rack SFC units do not have input circuit breakers; these must be supplied by the integrator.
Image Description: A photograph shows an ABB circuit breaker.
Isolation Transformer
The isolation transformer is used to match voltage requirements, transform the 3-wire inverter source to a 4-wire source, and isolate the power module common-mode voltage from the utility and load. It is required at either the input or output of the SFC. More details on specifying isolation transformers can be found in ABB document number 2UCD030000E003.
Control Features
Power Module Redundancy Feature
The modular design incorporates built-in redundancy. If a rectifier or inverter module fails, the master controller reduces output capacity to the remaining working modules. This reduction is typically transparent to the load, as the converter is usually not operating at full capacity. For example, a 2000kVA SFC with 16 module pairs can continue operating with one module failure, with only a 6.25% reduction in maximum output. This feature enhances reliability and availability, allowing for flexible planning of converter repair.
Parallel Load Sharing
The PCS100 SFC supports flexible paralleling with other voltage sources, including generators and multiple SFC units. Parallel load sharing is achieved through programmed frequency and voltage droop profiles, enabling converters to share power without additional communication signals. Different power ratings of SFC converters can be paralleled, with each delivering the same percentage of its rated power.
Power Flow Control
Advanced power flow control capabilities allow for the regulation of power flow between AC grids. This is particularly useful for interfacing co-generation plants to the grid, where controlled power flow is necessary.
Automatic Output Synchronisation
When SFC units are paralleled or connected to an AC bus with other generators, automatic output synchronization simplifies startup. The SFC checks for a live bus and synchronizes its output to the existing voltage and frequency before enabling inverter modules, ensuring a seamless transfer. If the bus is dead, the SFC ramps up voltage over 1 second for soft energization.
Remote Synchronisation
The PCS100 SFC includes a dedicated voltage sensing input for synchronizing its output to any three-phase voltage reference, useful for synchronizing separate busses before connecting them.
Output Short Circuit Protection
In the event of an output short circuit, the PCS100 SFC limits current to 200% of nominal for 2 seconds, allowing for downstream protection discrimination. If the fault persists, the SFC trips offline to prevent damage.
SFC Selection and Sizing
Type Code
This catalogue facilitates SFC selection based on the following information:
- Utility Voltage (V) and Utility Frequency (Hz)
- Load Capacity (kVA) and kW (or kVA and power factor)
- Load Frequency
- Ambient operating data
- IP rating requirements
The type code structure is outlined, indicating Product Series, SFC Family, Number of module pairs, Module type, Construction, Input location, and Options (Transformer, Extended I/O Card, Output Breakers).
Image Description: A screenshot of the ABB PCS100 SFC Sizing Tool application is displayed, showing input fields for project data, environmental data, and SFC specification data, along with calculation results and a generated type code.
Choosing the best transformer configuration
Industrial application
For input voltages between 380Vac and 480Vac, an output transformer offers the most flexible output, allowing for 3-wire or 4-wire output and various earthing options. An additional input transformer may be needed for voltage matching.
Image Description: A diagram shows an industrial application where LV 380V-480V input is converted by an SFC to power relocated 50Hz machinery in a 60Hz country. It depicts a main substation, PCS100 SFC with output transformer, and seaside terminal.
Shore to ship (Converter on harbor side)
When supplying power to berthed vessels, an SFC output transformer is necessary for voltage matching, isolation of common mode voltages, and crucially, galvanic isolation for the ship from the shore earth to prevent galvanic corrosion. An additional input transformer may be required for voltage matching.
Diagram Description: A diagram illustrates the shore-to-ship power supply. It shows a main substation connected to a PCS100 SFC with an output transformer, which then supplies power to a seaside terminal and a ship's bus (LV or MV). Input is LV or MV with transformer.
On-board Shore power
For converters installed onboard to provide power from the shore supply, an input transformer is required. This transformer provides voltage matching, isolation of common mode voltages, and galvanic isolation from shore earth to prevent galvanic corrosion. An additional output transformer may be needed for voltage matching or neutral requirements.
Diagram Description: A diagram shows a ship receiving power from shore. An input isolation transformer is connected to the ship's LV or MV bus, with the PCS100 SFC converting the power. The output is to the ship's LV bus or MV with transformer.
Sizing tool
ABB provides a Windows PC application for sizing the SFC. Users input load kVA, input/output voltages, and environmental data to determine the required SFC size and type code. The output can be saved as a CSV file.
Product Range
The PCS100 SFC product range is defined by the number of power module pairs used. The table below summarizes ratings for a typical PCS100 SFC system with 480Vac input voltage, 480Vac output voltage, and a 40°C maximum ambient temperature. Operation at different voltages may affect power ratings; consult the sizing tool for exact ratings.
Table Description: A table lists PCS100 SFC models from 03-01 to 03-16, detailing input and output kVA ratings, overload capacity (150% for 30s), and the number of module pairs required. It also shows the corresponding Type Code.
Note: PCS100-03-05 and larger models with termination cabinets have a fault rating of 65kA. Internal cabinets and wiring are protected by internal MCCBs. Smaller units require protection from the switchboard with a current-limiting MCCB with Isc less than 5 x SFC current.
Technical Specification
Input
| Parameter | Value |
|---|---|
| Voltage | 208-480 V ± 10% (or any voltage with input transformer) |
| Power System | 3-Phase TN |
| Frequency | 50 Hz or 60 Hz |
| Frequency range | ± 5 Hz |
| Max Continuous Voltage | 110% |
| Overload Capacity | 150% for 30 seconds |
| Overvoltage Category | III |
| Efficiency | 95% Typ |
| Current Harmonics | <3% THDi (at rated load) |
| Power Factor | Unity (adjustable) |
Output
| Parameter | Value |
|---|---|
| Capacity Rating | 125 kVA to 2000 kVA .9pf (higher power with parallel units) |
| Voltage | 208-480 V (or any voltage with input transformer) |
| Frequency | 50 or 60 Hz |
| Voltage Harmonics | < 2.5% THDv (linear load) |
| Overload Capability | 120% for 10 min* |
| 150% for 30 s | |
| Short Circuit limit | 200% for 2s |
| Voltage Accuracy | +/- 1% |
| Frequency Accuracy | +/- 0.1% |
General
| Parameter | Value |
|---|---|
| Enclosure IP rating | IP20 (IP42 Cabinet optional, cabinet only) |
| Operating panel (GDM) front IP rating | IP54 |
| Pollution degree rating | 2 |
| Operating Temperature | 0 °C to 40 °C |
| Cooling | Forced Air |
| Temperature De-rating | Above 40 °C, derate by 2% load per °C to a maximum of 50 °C |
| Capacity derating with elevation | -1.2% / 100 m for application above 1000 m |
| Maximum elevation | 3000 m maximum |
| Humidity | < 95% non-condensing |
| Noise | 75-85 dBA typical |
Electromagnetic Compatibility
| Parameter | Value |
|---|---|
| Environment | CISPR 11 class A |
Enclosures
| Parameter | Value |
|---|---|
| Materials | Electro-galvanized steel |
| Colour | RAL 7035 |
| Panel Thickness - Sides & Rear Panels | 1.5mm |
| 2mm | |
| Enclosure Access | Hinged doors with key lock (cabinet only) |
Standards
ISO 9001 Quality Assurance System, IEC62103 / EN 50178, CE Mark. Marine classifications available by request (DV, DNV, GL, ABS, CCS).
User Interface
| Parameter | Value |
|---|---|
| Type | 8.4" touch screen |
Control Interface
| Parameter | Digital Inputs (volt free contacts) | Digital Outputs (relay outputs) | Relay Output Ratings |
|---|---|---|---|
| Start | Stop / Reset | Running (NO) | 230 Vac 1 A |
| Warning (NO) | |||
| Fault (NC) |
Layout Plans & Elevations (Cabinet version)
The PCS100 SFC dimensions are detailed in the table. Two enclosure sizes are used: 400mm wide and 800mm wide. Multiple cabinets are combined for larger converters.
Table Description: A table provides dimensions (H, W, D in mm), weight (kg), heat dissipation (kW), air flow (m³/hr and CFM), and Type Code for PCS100 SFC models 03-01 through 03-16.
Front Elevations
Image Description: Three front elevation views of PCS100 SFC models are shown: PCS100 03-01, PCS100 03-04, and PCS100 03-05/03-06. Note indicates that models PCS100 03-05 and larger have a height of 2304 mm due to an additional cable tray.
Plan Views
Diagram Description: Plan views of the entire PCS100 SFC range are presented, illustrating the configuration of converter enclosures (C), transformer inclusions (Tx), and termination enclosures (T) for various models from PCS100 03-01-E/F to PCS100 03-16-E/F. Dimensions for each configuration are provided.
Layout Options
Enclosures can be placed side-by-side or back-to-back for larger models. Consult an ABB representative for layout requirements.
Diagram Description: An example of a back-to-back enclosure arrangement for a PCS100 03-16-E/F unit is shown, illustrating the placement of converter (C) and termination (T) enclosures.
Floor Requirements
All enclosures must be installed on a horizontal, fireproof surface. The slope between adjacent enclosures should not exceed ± 0.2°, and the elevation difference should not exceed ± 5 mm.
Layout Plans & Elevations (Rack version)
Racks are available for easy containerization and are supplied to accredited integrators. Racks have footprints of 1000mm x 800mm (for 1-4 module pairs) and 2000mm x 800mm (for 5-8 module pairs). Empty slots are covered by blanking plates. Modules are installed in two levels with AC busbars and DC links. Busbars can terminate at either end of the rack. A termination cabinet with AC/DC breakers is typically installed by the system integrator.
Diagram Description: An illustration shows a 16-module pair rack configuration for the PCS100 SFC. Separate diagrams show the GDM (Graphical Display Module), Master Module, and Interface assembly.
The master controller for each system is baseplate-mounted for integration into a control cabinet. Auxiliary supply of 230Vac and 26.5Vdc must be provided by the integrator.
Table Description: A table lists dimensions (H, W, D in mm, excluding termination busbars), weight (kg), heat dissipation (kW), air flow (m³/hr and CFM), and the number of module pairs for standard racks.
Power Module Type
PCS100 products utilize LV power modules with IGBTs and integrated sinusoidal filters. High-speed semiconductor fuses protect the AC and DC power connections of each module. Multiple modules are connected in parallel for higher power output.
Two module types are specified for SFC converters, corresponding to the isolation transformer's location: 'E' for Input Isolation Transformer systems (RFI Floating Rectifier, Grounded Inverter) and 'F' for Output Isolation Transformer systems (RFI Grounded Rectifier, Floating Inverter). An isolation transformer is required at either the input or output for correct operation.
Diagram Description: Two diagrams illustrate transformer configurations: 'Input Transformer Configuration (E type modules)' showing an E type rectifier and E type inverter with an input transformer, and 'Output Transformer Configuration (F type modules)' showing an F type rectifier and F type inverter with an output transformer. Both diagrams show the utility input and load output.
Transformers can also be used on both input and output for voltage matching.
Input Termination Location
Cabinet version
The following options are available for input connection location:
- PCS100 03-01 to PCS100 03-04 models have input and output via bottom entry only (BE).
- PCS100 03-05 to PCS100 03-16 models offer the option to place the input at either the left-hand (LH) or right-hand (RH) end of the converter (viewed from the front). The output connection is always at the opposite end to the input.
Rack version
The type code for rack versions includes options for rack configuration (e.g., Bxx for standard racks, number of 1000mm sections) and AC termination (e.g., Bx5 for left termination, Bx6 for right termination).
Diagram Description: Two examples of rack configurations are shown: PCS100-03-16E/F-B45 and PCS100-03-10E/F-B36, illustrating different termination and section arrangements.
Options
Options for the PCS100 are defined by additional codes (plus codes) appended to the type code.
Extended I/O Board +A100
The Extended I/O board provides additional I/O connections via the internal PCS100 CAN bus. It includes analog inputs (2), analog outputs (2), digital inputs (7), and thermal trip inputs (1).
Typical applications include remote synchronization, overload relay provision, analog power output signal, and full remote control via Modbus.
Image Description: A photograph shows the Extended I/O board with various connections and components.
Increased IP rating (cabinet version only)
An increased IP rating is possible for SFCs, from IP20 to IP42. IP42 features louver panels with 1mm IP42 screens on the front and rear, increasing cabinet depth by 100mm.
Image Description: Two diagrams show the difference between IP20 and IP42 enclosures for the SFC.
Output Circuit Breakers +OCB (cabinet version only)
Output circuit breakers are optional for SFC systems with 5 or more module pairs. They are recommended for protecting the SFC output when other generating sources are connected in parallel, or for isolating sections of the SFC. Output circuit breakers are not required for overload protection, which is handled electronically. They are necessary when the short circuit current exceeds 8kA, particularly in parallel SFC configurations.
Image Description: Two diagrams show SFC configurations with output circuit breakers: one for 1375kVA to 2000kVA +OCB, and another for 625kVA to 1250kVA +OCB.
Isolation Transformers
The PCS100 requires a dedicated isolation transformer for voltage matching and to counter common mode noise. Low voltage transformers up to 500 kVA can be ordered with the converter. Larger transformers can be sourced via ABB. Specific transformer models (+T125, +T250, +T375, +T500) are detailed with their capacity ratings and housing dimensions.
Image Description: A diagram shows an SFC cabinet with a +T250 transformer housed in a separate IP23 enclosure.
Transformer Specifications: Capacity Rating (100% of SFC rating), Type (Dry, copper windings, earthed core), Insulation (Class N, 200 °C), Typical Impedance (5%).
Neutral Generating Transformers
These transformers, also known as static balancers or zigzag transformers, are used when a neutral is required for three-phase three-wire SFC outputs. They connect to the SFC output to create a neutral point. Transformers are dual-rated for 50Hz and 60Hz operation. Options include +TZ10 (500A Neutral transformer) and +TZ10 (1000A Neutral transformer).
Examples of Systems
Image Description: Three examples of PCS100 SFC system configurations are shown:
- A single SFC cabinet with an integrated isolation transformer and master controller.
- An SFC cabinet with 3 module pairs and a master controller.
- A layout for a 1875 kVA SFC with output breakers.
Image Description: Two photographs show PCS100 SFC installations: two 1700kVA units onboard an FPSO at 45°C, and three 1875kVA units installed dockside for power supply.
Image Description: Two photographs show containerized PCS100 SFC solutions: two 1250kVA units containerized, and PCS100-03-10E-B35 & PCS100-03-10E-B36 integrated into a container solution.
