ABB PCS100 AVC-20 Active Voltage Conditioner

About This Document

ABB Power Conditioning

ABB is a leader in power conditioning technology, providing solutions for organizations worldwide to ensure continuous operation and protect against power quality issues. The ABB Power Conditioning portfolio includes static frequency converters, UPSs, and voltage/power conditioners designed for high reliability and cost-effectiveness. These solutions address power quality problems and stabilize networks across various applications, from data centers to industrial plants and microgrids, covering a wide range of power capacities (kVA) and supply voltages.

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Document Information

Copyright Notice

This manual is subject to change without notice. Reproduction, copying, or disclosure to third parties without written permission from ABB Ltd. is prohibited. Hardware and software are provided under license and may only be used, copied, or disclosed according to license terms.

Document Identification

Ownership: ABB Ltd., Power Conditioning Products

Document Number: 2UCD280000E002

Issue Date: 12/16/2022

Revision: Rev D

Contact Information

Address: ABB Ltd. 111 Main North Road, Napier, New Zealand.

Website: https://new.abb.com/ups

Contents

• About This Document
• Long Term Voltage Deviation – The Problem
• PCS100 AVC-20 Active Voltage Conditioner
• How it works
• PCS100 AVC-20 Benefits
• Industries and Applications
• Features
• Functional Description
• Technical Specification
• How to Select a PCS100 AVC-20
• PCS100 AVC-20 Model Range
• Layout Plans and Dimensions
• Options
• User Interface
• User Connections
• Installation Requirements
• Service and Technical Support
• Additional Documents

Long Term Voltage Deviation – The Problem

Utility networks in developing countries often lack sufficient reserve for peak demand, leading to power quality events. Remote areas or those at the end of distribution lines frequently experience voltage fluctuations due to weak utility grids. Commercial and industrial buildings in these environments must account for the impact of unstable utility networks on their operations.

Unlike voltage sags, which are temporary drops lasting 2-10 cycles, undervoltage can persist for minutes or hours. Fluctuating voltage negatively impacts productivity, operational consistency, product quality, and service delivery. It causes inefficient motor operation, poor resource utilization, increased machinery wear, and a higher rate of malfunctions.

Brownouts, overvoltage, and unbalanced voltage supplies can necessitate the use of costly backup systems like diesel generators. Unstable voltage hinders operational streamlining and resource optimization.

Image Description: A modern commercial building with a glass facade.

Image Description: An industrial facility with tall exhaust stacks.

Diagram Description: A line graph illustrating voltage fluctuation, showing an initial stable voltage followed by a significant dip (undervoltage) and then a return to a regulated, stable voltage.

PCS100 AVC-20 Active Voltage Conditioner

The PCS100 AVC-20 Active Voltage Conditioner provides efficient and effective voltage regulation for commercial and industrial applications requiring a clean, reliable, and consistent power supply. It is an inverter-based system designed to protect sensitive loads from voltage disturbances.

The unit offers fast, accurate overvoltage and undervoltage correction, continuous voltage regulation, and load voltage compensation, ensuring downstream equipment immunity from power quality events on the supply network.

Image Description: A large, modern industrial electrical cabinet system, composed of multiple connected units, designed for power conditioning.

Diagram Description: Two waveform diagrams. The first shows an 'Undervoltage Occurs' scenario with a fluctuating, lower-than-nominal input voltage. The second shows 'Undervoltage Regulated' with a stable, nominal output voltage, demonstrating the conditioner's function.

How it works

The PCS100 AVC-20 operates by using an injection transformer in series with the load. Two converters, not in the main current path, add or subtract voltage via this transformer as needed to maintain continuous, efficient, and accurate voltage regulation.

A redundant internal bypass circuit ensures continuous load supply from the utility in case of an overload or internal fault condition.

Diagram Description: A block diagram illustrating the PCS100 AVC-20 system. It shows a 3-phase utility supply connected via a distribution transformer and input circuit breaker to the PCS100 AVC-20. The PCS100 AVC-20 contains a rectifier, inverter, and an internal bypass. An injection transformer is in series with the load. The output is a 3-phase load. The bypass can be open or closed.

Diagram Description: Illustrates PCS100 AVC-20 operation during utility voltage deviation. Shows utility supply, PCS100 AVC-20, injection transformer, and load. A regulation voltage is injected by the inverter to maintain a stable load voltage, with the bypass open.

Diagram Description: Illustrates PCS100 AVC-20 internal bypass operation. In case of overload or fault, the bypass circuit is closed, directly connecting the utility supply to the load, bypassing the inverter.

PCS100 AVC-20 Benefits

• Reduce the cost of sag events: Closes the electrical compatibility gap by regulating voltage deviations, minimizing stress on equipment and increasing its lifetime. Full range voltage correction occurs within 20 milliseconds, making it ideal for large commercial buildings and sensitive industrial loads, especially in weaker networks.
• Improve plant operation: Regulates voltage to remove long-term undervoltage, overvoltage, and voltage imbalance, reducing waste and equipment damage. Enhances the quality of plant or facility operations.
• Faster return on investment: Achieves industry-leading efficiency exceeding 99%, minimizing electricity and cooling costs. With no energy storage, ongoing maintenance costs are low, contributing to a low total cost of ownership.
• Reduce damage to equipment: Protects expensive equipment by regulating voltage to eliminate long-term undervoltage, overvoltage, and voltage imbalance.

Image Description: A large, modern industrial electrical cabinet system, composed of multiple connected units, designed for power conditioning.

Industries and Applications

Industrial automation relies on advanced technology and requires a robust, continuous power supply. Weak utility grids or those lacking peak demand reserve can cause voltage fluctuations, disrupting operations, leading to wasted materials, long restart times, expensive repairs, and revenue losses. The PCS100 AVC-20 ensures a continuous, regulated utility voltage supply for stressed, unstable, or unreliable electric infrastructures.

The PCS100 AVC-20 offers complete power protection for commercial and industrial loads in sectors such as:

• Hotels and Resorts: Protects critical loads like lighting, heating, and cooling in areas with poor electrical infrastructure to ensure guest comfort and operational continuity.
• Commercial Buildings: Supports twenty-four-hour operations critical for global commerce by providing a reliable power supply.
• Food and Beverage: Safeguards highly automated facilities sensitive to power quality events, where high-quality electrical power is business-critical.
• Manufacturing: Ensures a constant power supply for production lines that consume significant power and rely on continuous processes, preventing risks to output and resources.

Image Description: A luxurious hotel building with multiple floors and balconies.

Image Description: A modern office building with a glass facade and multiple levels.

Image Description: An automated food processing facility with machinery and conveyor belts.

Image Description: A factory production line with robotic arms and machinery.

Features

• Continuous regulation: ±20% regulation with response less than 250 µs and full regulation in less than 20 milliseconds.
• Very high efficiency: Exceeds 99% even on partial loading.
• Small footprint: Industry-leading power density.
• Regenerative load support: Bidirectional power module design supports regenerative loads like lifts and cranes.
• Internal bypass: Guarantees continuity of load supply during PCS100 AVC-20 faults.
• Connectivity: Supports Ethernet, Modbus TCP, integrated web server, and E-mail notifications.
• Modular construction: Built on the proven PCS100 power converter platform with a large installed base, enabling fast and easy maintenance.
• Sophisticated control software: Based on 20 years of voltage conditioning industry experience.
• Multilingual graphical touch screen interface: Simple user controls with easy-to-understand event logging and voltage event data logging.

Image Description: A large, modern industrial electrical cabinet system, composed of multiple connected units, designed for power conditioning.

Functional Description

PCS100 AVC-20 Regulation Capabilities

The PCS100 AVC-20 regulates undervoltage and overvoltage within 20 milliseconds (one cycle), ensuring operational continuity during power quality events. Its undervoltage performance is adaptive to load conditions, allowing full regulation from down to 80% of nominal voltage based on unit loading or load power factor.

If utility voltage deviates beyond ±20%, the PCS100 AVC-20 continues to provide regulation as close to nominal voltage as possible, ensuring trouble-free operation of protected equipment. This adaptive approach allows users to select the unit based on load or required output voltage accuracy.

Diagram Description: A line graph titled "PCS100 AVC-20 Performance Curve" showing the relationship between PCS100 AVC-20 Input Voltage and Output Voltage for different load power factors (1.0 and 0.75), illustrating regulation capabilities.

PCS100 AVC-20 Operation Details

The following diagrams illustrate the PCS100 AVC-20's operation during utility disturbances and internal bypass events.

Utility Voltage Deviates from Nominal: When utility voltage deviates from nominal due to undervoltage, overvoltage, or unbalance, the inverter injects a regulation voltage via the injection transformer. The required energy for regulation is sourced from the utility through the PCS100 AVC-20 rectifier.

Diagram Description: Illustrates PCS100 AVC-20 operation during utility voltage deviation. Shows utility supply, PCS100 AVC-20, injection transformer, and load. A regulation voltage is injected by the inverter to maintain a stable load voltage, with the bypass open.

Internal Bypass Operation: In case of an overload or internal fault, the internal bypass circuit connects the utility supply directly to the load, bypassing the inverter.

Diagram Description: Illustrates PCS100 AVC-20 internal bypass operation. In case of overload or fault, the bypass circuit is closed, directly connecting the utility supply to the load, bypassing the inverter.

Technical Specification

Utility - Input

Load - Output

Performance

Internal Bypass

Injection Transformer

Environmental

Enclosure

Service

User Interface

Power Quality Event Monitor

Standards and Certifications

How to Select a PCS100 AVC-20

To select the correct size of the PCS100 AVC-20, consider the following:

• Utility voltage
• Power rating of the load (kVA and kW, or kVA and power factor)
• Target regulation range

Product tables can then be used to find the required model. Each model has a specific type code.

Type code

The PCS100 AVC-20 type code is provided in the product tables. The order code is unique to each model and specifies all components. Options can be added as plus (+) codes to the base code.

The type code structure is outlined as: PCS100-28 - 400 - 02B - 20 - L + SA, where parameters include Rated Voltage, Power Rating, Correction Performance, and Termination Side.

Type code Parameters:

• Rated Voltage: Standard is 400 V. Other voltages (e.g., 380V) are set via software and auxiliary transformer tapping.
• Power Rating: Based on power module pairs; each pair provides 500 kVA at rated voltage.
• Correction Performance: Defines the unit's correction capabilities.
• Termination Side: Specifies the location of power terminals (input/output) when viewed from the front.
• Options: Additional features described in the catalogue, added as plus codes.

PCS100 AVC Sizing Tool: ABB offers a Windows PC application to help dimension the correct PCS100 AVC-20 model for specific applications.

Image Description: A screenshot of the ABB PCS100 AVC Sizing Tool software interface, showing input fields for utility data, load capacity, power factor, and output parameters for configuring the PCS100 AVC-20.

For information on the sizing tool and its availability, contact your local ABB sales office.

PCS100 AVC-20 Model Range

400 and 415 V Application Voltage

380 V Application Voltage

Layout Plans and Dimensions

Side-by-side Layout Plans

The following plans detail the PCS100 AVC-20 for different frame sizes in a side-by-side layout. Plans are shown for the right (R) termination side. For a left (L) termination side, the transformer enclosure is mounted on the left of the controller enclosure.

1B frame size:

Diagram Description: Side-by-side layout plan for 1B frame size. Top view shows dimensions 844mm (33.23in) x 830mm (32.68in). Front view shows dimensions 2154mm (84.8in) x 844.2mm (33.24in). Right side view shows dimensions 830mm (32.7in) x 450mm (17.72in).

2B frame size:

Diagram Description: Side-by-side layout plan for 2B frame size, right termination side. Top view shows dimensions 809mm x 809mm. Front view shows dimensions 2154mm x 804mm.

3B frame size:

Diagram Description: Side-by-side layout plan for 3B frame size, right termination side. Top view shows dimensions 809mm x 809mm. Front view shows dimensions 2154mm x 804mm.

4B, 5B and 6B frame size:

Diagram Description: Side-by-side layout plan for 4B, 5B, and 6B frame sizes. Top view shows dimensions 809mm x 1204mm. Front view shows dimensions 2154mm x 804mm.

Back-to-back Layout Plans

These plans relate to the optional Back-to-Back layout with left (L) or right (R) termination side options. The exact termination side is defined by 'L' or 'R' in the product type code.

2B frame size:

Diagram Description: Back-to-back layout plan for 2B frame size, showing front and top views.

3B frame size:

Diagram Description: Back-to-back layout plan for 3B frame size, showing front and top views.

Clearance

Required clearances for all enclosures:

• 200 mm (minimum) above.
• 1500 mm (recommended) clearance in front.
• 200 mm (minimum) clearance at the rear for airflow.
• No side clearance required.

Side clearance to the wall where hinges are located: minimum 400 mm is recommended to allow doors to open sufficiently (120°) for module replacement.

Diagram Description: Diagrams illustrating required clearances: 200mm (7.9 inches) above and rear, 1500mm (59 inches) in front. Side clearance of 400mm (15.8 inches) is recommended for door opening.

Weights

Options

The following options are available for the PCS100 AVC-20 enclosures:

Back-to-back Layout (BB)

PCS100 AVC-20 models larger than 500 kVA consist of Controller and Transformer Enclosures. The standard layout is side-by-side. The optional Back-to-back layout (+BB) installs the Transformer Enclosure behind the Controller Enclosure.

Roof Kit (RK)

The Roof Kit provides increased protection (IP21) against liquid ingress for indoor use. It requires a 200mm clearance above the enclosure and is shipped separately for on-site assembly.

Image Description: An illustration of the PCS100 AVC-20 enclosure with an optional Roof Kit installed on top.

ShellPlus (SP)

The ShellPlus option allows for easier power connections for top cable entry.

Side Car (SC)

An alternative option for easier power connections, usable for both top and bottom cable entry.

Side Aperture (SA)

Enclosures can be supplied with a pre-cut side aperture for easier side cable or bus bar connection to a maintenance bypass. This option requires a maintenance bypass adjacent to the PCS100 AVC-20.

Image Description: Illustration of a PCS100 AVC-20 enclosure with a pre-cut Side Aperture, facilitating side cable or bus bar connection.

Top Entry Cable Duct (CD)

A 200 mm Top Entry Cable Duct accommodates supply and load cables or bus bars for frame sizes 2B. It mounts on the side of the transformer terminals and includes a top gland plate and cable support.

Image Description: Illustration of the PCS100 AVC-20 enclosure with the Top Entry Cable Duct accessory mounted on the side.

Termination Enclosure (TE)

The 400 mm Termination Enclosure provides easier power connections or matches enclosure sizes with other equipment. It mounts on the side of the transformer terminals and includes a plinth and door for top or bottom cable/bus bar connection, along with cable support and a gland plate.

Image Description: Illustration of the PCS100 AVC-20 enclosure with the Termination Enclosure accessory mounted on the side.

Dummy Enclosure (DMY)

400 mm Dummy enclosures are empty units for cosmetic purposes, such as filling gaps in back-to-back layouts.

Image Description: Illustration of the PCS100 AVC-20 enclosure with a Dummy Enclosure, used for cosmetic filling in back-to-back layouts.

Termination Palms (TPx)

Standard termination palms are horizontal bars. The TPx option provides vertical bars with IEC or NEMA standard dimensions and hole positions. IEC standard is TPI, NEMA standard is TPN.

Image Description: Illustrations showing standard horizontal termination palms and optional vertical TPx termination palms for cable connections.

Redundant Power Supply Unit (PS)

This option includes an Auxiliary Master Module with two PSUs for redundant DC feed. An internal status signal monitors PSU health, providing warnings if a PSU fails. The PSUs share the DC supply, with one taking over if the other fails.

User Interface

Graphic Display Module (GDM)

The primary user interface is the 10.1" touchscreen Graphic Display Module (GDM). It offers an intuitive, user-friendly interface for configuration, system status display, parameter access, and event history. The mimic diagram provides a clear view of the system status.

Supported languages include: English, French, Italian, Malaysian, Turkish, Russian, German, Vietnamese, Spanish, Simplified Chinese, Japanese, Traditional Chinese, Swedish, Indonesian, Portuguese, Arabic, and Korean.

Diagram Description: A diagram of the Graphic Display Module (GDM) interface, showing input voltage (V1-2, V2-3, V3-1), frequency, output voltage, and power status (S, P).

Remote Monitoring

The GDM provides remote access for monitoring. Available connections include:

Remote Web Pages: Web pages accessible via a browser, similar to the GDM, allowing remote status and parameter viewing. Event history and service logs can also be downloaded. Multiple languages are supported.

Modbus TCP: Provides read-only access to operating parameters like voltages, currents, and power levels via the GDM's Ethernet port.

E-mail: Configurable for sending notifications on power quality events or internal system events (faults, warnings). Service logs can be automatically sent to ABB Service via email.

Diagram Description: A network diagram showing connections for remote monitoring: Plant Control System, Remote PC, Local Ethernet, Network Switch, Firewall, VPN, and Email, all communicating via Modbus TCP or Ethernet.

User Connections

Power Connections

Utility supply (input) and load (output) connections are made directly to the Injection Transformer terminals within the enclosure.

Image Description: An illustration of the PCS100 AVC-20 enclosure, highlighting the location of input (Utility Supply) and output (Load) terminals.

Control Connections

Control connections for local control or system monitoring are located on the Auxiliary Master Module in the Master Controller Enclosure.

Diagram Description: A wiring diagram detailing control connections for customer monitoring and alarm systems, including relay outputs and digital inputs for RUN, WARNING, FAULT, TX ALARM, START, STOP/RESET/INHIBIT, and LOOP status.

Installation Requirements

Input Circuit Protection

The PCS100 AVC-20 relies on upstream protection (circuit breaker) for current overload and short circuit. Overload protection should not exceed the rated load current. Short circuit and arc fault calculations must account for the PCS100 AVC-20's impedance (typically < 2.5%). Circuit breakers should trip instantaneously on short circuit or arc fault currents. Coarse ground fault detection is recommended for high current systems.

The unit is designed to withstand significant short circuit currents. For 1B frame sizes, current-limiting MCCBs or fuses are required. ABB T6 series or equivalent are suitable.

* If network short circuit capability exceeds AVC rating, an upstream breaker is needed to limit fault current.

The PCS100 AVC-20 can sustain fault currents up to 2000% for 200 ms and can be returned to service immediately. Higher fault currents may require service.

Arc Fault and Protection Recommendation

Arc faults pose risks of injury from burns, pressure, and debris. ABB strongly recommends MCCB or ACB for arc protection. High energy release and heat necessitate the use of personal protective equipment when working near live equipment.

Maintenance Bypass

ABB recommends fitting a maintenance bypass (not supplied) to allow maintenance without load disruption. ABB requires input/output breakers of the bypass to be lockable for service personnel.

Floor Requirements

Install enclosures on a horizontal, fireproof surface. Ensure adjacent enclosures have a slope change of no more than ± 0.2° and an elevation difference of no more than ± 5 mm.

Location

The PCS100 AVC-20 is designed for restricted access locations and connection by fixed wiring.

Service and Technical Support

ABB Power Conditioning offers global service and support for installation and commissioning of PCS100 products.

Comprehensive Global Services Portfolio

ABB services cover the entire product lifecycle, including pre-purchase engineering, installation, commissioning, technical support, training, preventive and corrective maintenance, spare parts, retrofit, refurbishment, global support in over 100 countries, spare part availability, and on-site repairs. A 24x365 local support line is available.

Custom Tailored Service Contracts

Service contracts can be tailored to customer needs, offering improved cost control, operational efficiency, and extended product lifetime. Contracts can be established at any stage of product ownership.

Life Cycle Management

ABB's life cycle management model maximizes equipment value and maintenance investment by ensuring high availability, reducing unplanned repair costs, and extending system lifetime. This includes spare parts, expertise, efficient product support, and functionality upgrades.

Training

Product training covers installation, commissioning, and maintenance, offered at ABB Universities or customer sites. Training can be included in ABB service contracts.

Engineering and Technical Support

ABB's engineering team provides necessary electrical, protective, and monitoring equipment for high energy continuity and superior power quality. Services include pre-purchase engineering for selection and integration, customer assistance in sizing and modeling, and other technical support via phone, email, or on-site visits. The PCS100's internal bypass design enhances reliability and availability.

Additional Documents