ABB UNITROL1020 3BHE036163R6106 Brushless Excitation Module

Description

Product Model: UNITROL 1020
Ordering / Type Number: 3BHE036163R6106
Product Brand: ABB
Product Series: UNITROL 1000 family, brushless / indirect excitation
Product Features (per supplier sources):

• Capable of 10 A DC continuous output, with higher peak current capability.
• Supports dual-channel, advanced load sharing between machines in parallel, rotating diode monitoring, automatic synchronisation, Ethernet + RS-485 + USB interfaces.
• Compact, robust design suited for harsh environments (wide temp, vibration).
• Part of ABB’s proven automatic voltage regulator family; designed for small to medium synchronous machines

Applications & Industry Context

In power plants, industrial generation systems, and backup / standby power installations, the stability of generator output voltage under varying load and transient conditions is mission critical. A good automatic voltage regulator (AVR) must respond rapidly to changes, minimize overshoot, handle parallel machines, and survive harsh environmental stressors. UNITROL 1020 (3BHE036163R6106) is ABB’s solution in the small-to-medium synchronous generator space, bridging the gap between rugged field operation and modern communication & control demands.

You’ll commonly see it in installations such as:

• Diesel or gas generator sets in industrial plants, providing regulated voltage to auxiliaries and critical systems.
• Renewable or hybrid microgrid systems where a synchronous machine is part of the power mix.
• Marine auxiliary generators, where compactness, vibration resistance, and robustness are essential.
• Upgrades or retrofits of aging AVR systems in plants where replacing the entire cabinet is not viable.

Because ABB’s UNITROL family is widely deployed (over 40,000 installations), engineers often specify the 1020 module for both new builds and spares inventories—benefiting from familiarity, support infrastructure, and spares availability.

Product Role & System Fit

UNITROL 1020 is a brushless / indirect excitation AVR. In your generator control architecture, it sits between the generator’s voltage transformer (VT), current/field sensing circuits, the power exciter circuits (IGBT, rotating diodes, or pilot exciter), and the supervisory / automation system.

When integrated:

• It ensures tight voltage regulation under varying loads.
• It provides dual-channel control, meaning redundancy or load sharing logic is supported.
• In multi-generator setups, its load sharing / paralleling features coordinate output across machines.
• It supports communication to higher-level systems via Ethernet, RS-485 (Modbus), or USB (for diagnostics/commissioning).
• It interacts with synchronisation logic, rotating diode monitoring logic, protection interfaces and I/O events.

In many retrofits, this module is chosen for drop-in replacement, given correct mechanical mounting, wiring compatibility, and parameter migration.

Technical Features & Benefits

Here’s a breakdown of key features (from supplier sources) and how they matter in real installations:

10 A Continuous / Peak Current Capability

Many sources list the UNITROL 1020 (with this ordering code) as delivering a continuous 10 A DC output, with peak current up to 15 A depending on the duty cycle.
Benefit: Suits machines with moderate excitation demand; ample margin for transient loads or boosting.

Voltage Ratings & Efficiency

Documentation often cites a rated voltage of 350 V DC and peak voltage of 525 V DC capabilities.  Efficiency is noted above 95%, minimizing power loss

Environmental & Mechanical Design

Operating temperature range: −20 °C to +55 °C; storage: −40 to +70 °C. Vibration, shock and IP protection are addressed in test reports.
Benefit: Reliable in industrial and marine contexts where heat, vibration or ambient extremes occur.

Communications & Diagnostics

Supports Ethernet (100 Mbit), RS-485 (Modbus load sharing), USB (parameter download), and integration with ABB’s CMT1000 commissioning tool.
Benefit: Simplifies configuration, real-time monitoring, event logging and diagnostics, reducing commissioning time.

Dual Channel & Paralleling Logic

The design includes built-in logic for distributing load between machines running in parallel, synchronisation, rotating diode supervision, and redundancy.
Benefit: Ensures stable parallel operation, enhances system robustness in multi-machine installations.

In practice, swapping older analog AVRs with a modern UNITROL 1020 often improves voltage recovery time and reduces oscillations during load steps. The ability to log events (faults, over/under voltage events) helps maintenance engineers detect drift before a failure.

Technical Specifications Table

Related Models

• UNITROL 1005 – Lower power version (≈5 A) for small machines.
• UNITROL 1010 – Mid-power variant (~10 A) sitting below 1020 in output capacity.
• Other variants of the UNITROL 1020 (e.g. FULL, PSS versions) with additional features.

When specifying or ordering a spare, ensure the exact ordering code 3BHE036163R6106 and any firmware or variant options (PSS, communications, channel count) match.

Installation & Maintenance Insights

From field experience and available test documents (e.g. Wartsila test report) here are practical tips:

• Verify wiring & polarity before startup – Excitation systems handle high currents; miswired field circuits or reversed polarity cause damage.
• Grounding & shielding – Ensure proper earthing and shielding of control cables to reduce noise or interference, especially for analog sensors.
• Parameter migration – When replacing an old AVR, export and load parameter sets (voltage setpoint, speed compensation, limits) to minimize commissioning time.
• Fault / event log review – After installation, review event history (OV/UV trips, overcurrent, etc.) to ensure behavior is within expected margins.
• Load sharing tests – In parallel systems, test load distribution across machines during varying load steps to ensure correct load sharing logic.
• Spare module readiness – Keep a properly configured spare UNITROL 1020 (matching code, firmware) in your parts inventory; swapping is often faster than in-field repair.
• Periodic inspections – Inspect cooling paths, connectors, terminal torque, signs of overheating or discoloration, especially in high ambient settings.