Description
Key Technical Specifications
- Model Number: ABB FC95-22 HESG44888R22
- Manufacturer: ABB
- Device Type: 3-phase full-wave thyristor (SCR) converter (rectifier + inverter capable)
- Thyristor Configuration: 6 x high-power SCRs (3-phase bridge)
- Rated Current: 2200A (continuous), 4400A (peak surge, 10ms)
- Rated Voltage: 4200V DC (reverse blocking voltage)
- Control Signal Input: ±10V DC (phase angle control)
- Operating Temperature: -20°C to 110°C (-4°F to 230°F)
- Storage Temperature: -40°C to 150°C (-40°F to 302°F)
- Isolation: 4kV AC (module-to-ground, 1-minute withstand)
- Thermal Resistance: 0.05°C/W (junction-to-heatsink)
- Mounting: Direct heatsink mounting (compatible with DCS800 drive skids)
- Cooling Requirement: Liquid cooling (minimum 30 L/min flow rate)
- Power Consumption: 5W (control circuit), 12kW (power dissipation @ full load)
- Connector Type: Heavy-duty copper busbar terminals (M20 studs)
- Weight: 28 kg (61.7 lbs)
- Protection Features: Overcurrent, overvoltage, thermal overload, and reverse polarity protection
ABB FC95-22 HESG44888R22
Field Application & Problem Solved
In heavy-industry settings—steel mills, mining operations, and large manufacturing plants—controlling high-power motors (1MW+) requires robust power conversion that can handle extreme currents and voltages. The challenge? Standard converter modules lack the current capacity to drive large motors, while low-voltage designs suffer from efficiency losses and thermal failure under continuous high-load operation. Many modules also fail to provide smooth phase-controlled conversion, leading to motor torque ripple and mechanical stress. The ABB FC95-22 HESG44888R22 solves these critical issues with high-current thyristor technology, rugged thermal design, and precise phase control.
You’ll find this module as the power core of ABB DCS800 drive systems, powering large motors like conveyor drives in mining operations, rolling mill motors in steel plants, or water pump motors in municipal treatment facilities. It’s used in rectifier mode to convert AC grid power to DC for motor armature supply, and in inverter mode for regenerative braking (feeding excess energy back to the grid). In steel mills, it controls the speed of hot rolling mill motors, where its 2200A continuous current rating handles the high torque demands of shaping steel. In mining, it drives longwall shearer motors, leveraging its liquid cooling system to withstand the high ambient temperatures of underground mines.
Its core value is power density and reliability. The 2200A current rating and 4200V voltage tolerance make it suitable for the largest industrial motors, eliminating the need for parallel module configurations (reducing complexity and cost). The phase-controlled SCRs provide smooth DC output, minimizing motor torque ripple and extending equipment life. Liquid cooling ensures stable thermal performance even at full load, preventing overheating—a common failure point in air-cooled modules. For operators, this means reliable motor control, reduced maintenance downtime, and energy savings from regenerative braking—critical in energy-intensive heavy industries.
Installation & Maintenance Pitfalls (Expert Tips)
- Liquid Cooling System Priming (Air Bubbles = Thermal Failure): The module relies on liquid cooling, but rookies often skip proper system priming. Air bubbles in the cooling circuit block flow, causing hotspots and SCR overheating. Prime the cooling system by bleeding air from all high points (use ABB’s recommended bleeder valves) and verify flow rate with a inline flow meter (minimum 30 L/min). Check for leaks post-priming—even small leaks lead to coolant loss and thermal shutdown. Use only ABB-approved coolant (50/50 ethylene glycol/water mix) to prevent corrosion and scaling.
- Busbar Torque & Contact Pressure (Under-Torquing = Arcing): The M20 busbar studs carry 2200A current, so insufficient torque creates high-resistance connections that arc during operation. Rookies often use manual wrenches instead of calibrated torque tools. Torque copper busbars to 120 Nm and aluminum busbars to 130 Nm using a torque wrench with a crowfoot adapter. Retorque after the first 100 hours of operation—thermal cycling loosens connections, increasing resistance and heat generation.
- Control Signal Wiring (EMI = Erratic Conversion): The ±10V DC control signal is sensitive to electromagnetic interference (EMI), but rookies often run control wires alongside high-voltage busbars. EMI induces noise, causing erratic phase angle control and unstable motor speed. Use double-shielded twisted-pair (DSTP) cable for control signals, route them at least 1 meter away from power cables, and ground both shields (inner shield at module end, outer shield at controller end). For runs over 50 meters, install an EMI filter at the module input to suppress noise.
- Pre-Commissioning SCR & Diode Testing (Latent Faults = Catastrophic Failure): New modules can have hidden SCR or freewheeling diode defects, but rookies often skip testing. Use a high-voltage thyristor tester to verify each SCR’s forward blocking voltage (≥4200V) and gate trigger response. Test freewheeling diodes for reverse leakage (should be <10μA). A faulty SCR or diode causes unbalanced three-phase conversion, leading to motor vibration, module overload, or even motor winding damage. Replace any defective components before commissioning—never operate the module with compromised parts.
ABB FC95-22 HESG44888R22
Technical Deep Dive & Overview
The ABB FC95-22 HESG44888R22 is a high-power thyristor converter module designed for large-scale motor control in ABB’s DCS800 drive systems. Its core is a 3-phase full-wave bridge configuration of 6 high-voltage SCRs, each rated for 2200A continuous current and 4200V reverse blocking voltage. The SCRs use planar technology with glass passivation, ensuring high surge tolerance and long-term reliability under extreme electrical stress.
The module operates in two modes: rectifier (AC-to-DC) and inverter (DC-to-AC). In rectifier mode, phase angle control (0-180 degrees) adjusts the SCR firing timing to regulate DC output voltage/current for motor armature supply. In inverter mode, it converts DC power from regenerative braking back to AC for grid feed-in, reducing energy waste. The control circuit uses optical isolators to separate low-voltage control signals from high-voltage power circuits, preventing ground loops and ensuring operator safety.
Thermal management is a critical design element: the module’s base plate is a copper heatsink with integrated cooling channels that distribute coolant evenly. The SCRs are directly bonded to the base plate using high-temperature solder, minimizing thermal resistance (0.05°C/W). A built-in temperature sensor monitors the base plate temperature, sending a signal to the drive controller to reduce load or trigger an alarm if temperatures exceed 110°C.
The module includes freewheeling diodes across each SCR to protect against voltage spikes during commutation. Internal snubber circuits (RC networks) dampen transient voltages, preventing SCR damage from switching surges. The 4kV AC isolation rating ensures safe operation alongside high-voltage grid components, while surge protection (±20kV) shields the module from grid transients.
Built for heavy-industry ruggedness, the module features a welded steel housing with IP54 protection, shielding against dust and water spray. It withstands vibration (up to 5g at 10-2000Hz) and thermal cycling (-20°C to 110°C), suitable for harsh environments like steel mills and mines. The module’s hot-swappable design (in redundant DCS800 configurations) allows replacement without shutting down the entire drive system, minimizing downtime. Its long service life (15 years typical) aligns with industrial motor maintenance cycles, reducing lifecycle costs and replacement frequency.
