ABB ACS880-87CC User manual

—
ABB WIND TURBINE CONVERTERS
ACS880-87CC wind turbine converters
Hardware manual

ACS880-87CC wind turbine
converters
Hardware manual
Table of contents
1. Safety instructions
4. Mechanical installation
6. Electrical installation
3AXD50000466948 Rev B
EN
Original instructions
EFFECTIVE: 2021-06-07

Table of contents
1 Safety instructions
11Contents of this chapter ...........................................................................
11Use of warnings and notes .......................................................................
12General safety in installation, start-up and maintenance ....................................
14Electrical safety in installation, start-up and maintenance ...................................
14Precautions before electrical work ...........................................................
15Additional instructions and notes .............................................................
15Fiber optic cables ...............................................................................
16Opening and disconnecting the main circuit breaker .....................................
18Disconnecting the charging circuit from the main circuit ..................................
19Disconnecting the auxiliary power supply ..................................................
20Grounding .......................................................................................
21Work on the liquid cooling system ...............................................................
2 Introduction to the manual
23Contents of this chapter ...........................................................................
23Target audience ....................................................................................
23Categorization by frame size and option code .................................................
24Quick installation, commissioning and operation flowchart ..................................
25Terms and abbreviations ..........................................................................
26Related documents ................................................................................
3 Operation principle and hardware description
27Contents of this chapter ...........................................................................
27Operation principle .................................................................................
28Generator control ..................................................................................
29Overview diagram of the wind turbine converter ..............................................
29Single converter ................................................................................
30Parallel converters .............................................................................
31Layout drawing .....................................................................................
34Overview of power and control connections ...................................................
34Single converter ................................................................................
35Parallel converters .............................................................................
36Circuit boards .......................................................................................
36Single converter ................................................................................
37Parallel converters .............................................................................
39BAMU board ........................................................................................
39Type designation labels ...........................................................................
39Single converter ................................................................................
40Parallel converters .............................................................................
41Type designation key ..............................................................................
42Basic code .......................................................................................
42Option codes (plus codes) ....................................................................
Table of contents 5

4 Mechanical installation
45Contents of this chapter ...........................................................................
45Safety instructions .................................................................................
46Checklist before mechanical installation ........................................................
47Moving the converter package ...................................................................
47Moving the converter package by fork-lift ...................................................
47Moving the converter on rollers ..............................................................
48Unpacking ...........................................................................................
48Lifting the converter ................................................................................
50Placing the converter ..............................................................................
51Fastening the cabinet to the floor ................................................................
51Internal cooling circuit .............................................................................
51Lifting the door .....................................................................................
51Miscellaneous ......................................................................................
51Cable duct in the floor below the cabinet ...................................................
51Electric welding .................................................................................
5 Planning the electrical installation
53Contents of this chapter ...........................................................................
53Selecting the grid disconnecting device ........................................................
54Checking the compatibility of the generator and the converter .............................
54Protecting the generator insulation and bearings ..........................................
55Selecting the power cables .......................................................................
55General rules ....................................................................................
55Sufficient conductivity of the protective conductor .........................................
56Typical power cable sizes .....................................................................
56CE cables ....................................................................................
57UL cables ....................................................................................
57Alternative power cable types ................................................................
57Power cable types for limited use ........................................................
58Not allowed power cable types ...........................................................
58Generator cable shield .....................................................................
58Single core vs multicore cables in grid cabling .............................................
59Additional US and Canada requirements ...................................................
59Conduit .......................................................................................
59Armored cable / shielded power cable ...................................................
59Selecting the control cables ......................................................................
59General rules ....................................................................................
60Relay cable ......................................................................................
61Routing the cables .................................................................................
62Control cable ducts .............................................................................
62Protecting the converter installation .............................................................
62Protecting the grid cable in short-circuit situations ........................................
62Protecting the generator and generator cable in short-circuit situations ...............
62Protecting the converter, generator cable and grid cable against thermal overload ...
62Protecting the converter against ground faults in the generator or generator cable ...
63Protecting the converter against ground faults in the converter or grid cable .........
63Implementing the emergency stop function ....................................................
63Implementing the grid fault ride-through function .............................................
63Supplying power for the auxiliary circuits .......................................................
63Using a safety switch between the converter and generator ................................
6 Table of contents

63Protecting the contacts of relay outputs ........................................................
6 Electrical installation
65Contents of this chapter ...........................................................................
65Checking the insulation of the assembly .......................................................
65Converter ........................................................................................
65Grid cable ........................................................................................
66Generator stator and generator cable .......................................................
66Connecting the grid cables .......................................................................
66Connection diagram ............................................................................
67Connection procedure .........................................................................
68Connecting the generator cables ................................................................
68Connection diagram ............................................................................
68Connection procedure .........................................................................
71Connecting the external power supply cable for the auxiliary circuit .......................
72Connecting the control cables ...................................................................
72Default I/O connection diagrams .............................................................
7 Installation checklist
73Contents of this chapter ...........................................................................
73Before you start ....................................................................................
74Checklist .............................................................................................
8 Maintenance
75Contents of this chapter ...........................................................................
75Maintenance intervals .............................................................................
77Maintenance timers and counters ...............................................................
77Cabinet ..............................................................................................
77Cleaning the door air inlets ...................................................................
78Cleaning the door air inlets and outlets (auxiliary control cubicle) ......................
78Cleaning the outlet (door or roof) filters .....................................................
78Power connections ................................................................................
78Tightening .......................................................................................
79Fans ..................................................................................................
79Replacing the cooling fan of the converter module ........................................
81Replacing the fan of the main breaker cubicle .............................................
82Replacing the cooling fan of the auxiliary control cubicle ................................
83Replacing the cooling fan of the LCL filter cubicle .........................................
84Fuses ................................................................................................
84Replacing the DC fuses .......................................................................
85Replacing the AC fuses .......................................................................
86Converter module ..................................................................................
86Replacing the converter module .............................................................
92Capacitors ...........................................................................................
92BCU control unit ....................................................................................
92Replacing the memory unit ...................................................................
92Replacing the real-time clock battery ........................................................
92Replacing the SD/SDHC memory card .....................................................
93Replacement illustration .......................................................................
93Main circuit breaker ................................................................................
Table of contents 7

9 Technical data
95Contents of this chapter ...........................................................................
95Ratings ..............................................................................................
95Definitions .......................................................................................
96Derating ..........................................................................................
96Ambient temperature derating ............................................................
96Altitude derating .............................................................................
96Type equivalence table ............................................................................
97Fuses ................................................................................................
97Main circuit AC fuses ..........................................................................
97Main circuit DC fuses ..........................................................................
97Fuses for the voltage measurement board BAMU ........................................
97Fuses of the DC chopper ......................................................................
97F4 fuses ..........................................................................................
97Dimensions, weights and free space requirements ...........................................
98Losses, cooling data and noise ..................................................................
98Internal cooling circuit data ...................................................................
98Terminal and lead-through data for the grid connection ......................................
98Tightening torques .............................................................................
98Terminal and lead-through data for the generator cable .....................................
99Grid specification ...................................................................................
99Requirements for the grid connection ...........................................................
99Generator connection data .......................................................................
99BCU control unit ....................................................................................
100Efficiency ............................................................................................
100Degree of protection ...............................................................................
100Environmental and corrosion classification ....................................................
101Ambient conditions ................................................................................
102Materials .............................................................................................
102Auxiliary circuit current consumption ............................................................
103Applicable standards ..............................................................................
103CE marking .........................................................................................
103Compliance with the European Low Voltage Directive ....................................
103Compliance with the European EMC Directive ............................................
103Compliance with the European Machinery Directive .........................................
103Regulatory Compliance Mark (RCM) ...........................................................
104EAC (Eurasian Conformity) marking ............................................................
104Compliance with EN 61800-3:2004/A1:2012 ..................................................
104Definitions .......................................................................................
104Category C4 .....................................................................................
105ETL marking ........................................................................................
105WEEE mark .........................................................................................
105GL2010 ..............................................................................................
105Disclaimers .........................................................................................
105Generic disclaimer .............................................................................
105Cybersecurity disclaimer ......................................................................
10 BCU-x2 control unit
107Contents of this chapter ...........................................................................
107General ..............................................................................................
107BCU control unit ................................................................................
8 Table of contents

108Layout and connections ...........................................................................
110Connector data .....................................................................................
11 BCU-x5 control unit
113Contents of this chapter ...........................................................................
113General ..............................................................................................
113BCU control unit ................................................................................
114Layout and connections ...........................................................................
117Connector data .....................................................................................
12 Dimension drawings
119Contents of this chapter ...........................................................................
13 Cooling and heating
123Contents of this chapter ...........................................................................
123Hardware description ..............................................................................
123General ..........................................................................................
123Diagram of the internal cooling and heating circuit ........................................
125Planning the cooling system .....................................................................
125Connection to a cooling unit ..................................................................
125General requirements ......................................................................
125Coolant temperature control ...............................................................
126Mechanical installation ............................................................................
126Connecting the internal cooling circuit to a customer cooling unit ......................
126Connecting the liquid pipes ................................................................
126Filling up and bleeding the internal cooling circuit ............................................
127Converters with a customer cooling unit ....................................................
128Draining the internal cooling circuit ..............................................................
128Cooling station control ............................................................................
129Specifications .......................................................................................
129Temperature limits ..............................................................................
130Pressure limits ..................................................................................
130Water quality ....................................................................................
130Freeze protection and corrosion inhibition ..................................................
131Coolant concentration ......................................................................
131Coolant mixture quality .....................................................................
131Approved coolants ..........................................................................
131Materials .........................................................................................
132Cold start ............................................................................................
132First start in a commissioning .................................................................
132Normal start and start after blackout ........................................................
Further information
Table of contents 9

10

Safety instructions
Contents of this chapter
This chapter contains the safety instructions which you must obey when you install and
operate the converter, and do maintenance on the converter. If you ignore the safety
instructions, injury, death or damage can occur to the converter, the generator or other
adjoining equipment. Read the safety instructions before you work on the unit.
Use of warnings and notes
Warnings tell you about conditions which can cause injury or death, or damage to the
equipment. They also tell you how to prevent the danger. Notes draw attention to a particular
condition or fact, or give information on a subject.
The manual uses these warning symbols:
WARNING!
Electricity warning tells about hazards from electricity which can cause injury or
death, or damage to the equipment.
WARNING!
General warning tells about conditions, other than those caused by electricity,
which can cause injury or death, or damage to the equipment.
WARNING!
Electrostatic sensitive devices warning tells you about the risk of electrostatic
discharge which can cause damage to the equipment.
1
Safety instructions 11

General safety in installation, start-up and maintenance
These instructions are for all personnel that install the converter and do maintenance work
on it.
12 Safety instructions
3

WARNING!
Obey these instructions. If you ignore them, injury or death, or damage to the
equipment can occur.
•Use safety shoes with a metal toe cap. Use protective gloves.
•Use protective eyewear when working with the liquid cooling system.
•Handle the converter modules carefully:
•Lift the module with a lifting device only. Use the designated lifting points.
See the lifting instructions.
•Do not tilt the module. It will overturn very easily because it is heavy and its
center of gravity is high.
•Modules running on wheels: Make sure that the module does not topple over
when you move it on the floor: Whenever possible secure the module also
with chains. Do not leave the module unattended on a sloping floor.
•Beware of hot surfaces. Some parts, such as heatsinks of power
semiconductors, remain hot for a while after disconnection of the electrical
supply.
•Keep the converter in its package or protect it otherwise from dust and burr
from drilling and grinding until you install it. Protect also the installed converter
against dust and burr. Electrically conductive debris inside the drive can cause
damage or malfunction.
•Vacuum clean the area below the converter before the start-up to prevent the
converter cooling fans from drawing the dust inside the converter.
•Do not cover the air inlet and outlet when the converter is running.
•Make sure that there is sufficient cooling. Before power switch-on, make sure
that the liquid cooling circuit is filled up with coolant. Running the external cooling
pump dry will damage it. Also the converter will not cool down. See the converter
hardware manual.
•Before you connect voltage to the converter, make sure that the cabinet doors
are closed. Keep the doors closed during operation.
• Before you adjust the converter operation limits, make sure that the generator
and all driven equipment can operate throughout the set operation limits.
• The maximum number of converter power-ups is five in ten minutes. Too
frequent power-ups can damage the charging circuit of the DC capacitors.
•Make sure that safety circuits (for example, emergency stop, if any) are validated
at start-up.
• Beware of the cooling fan blades. The fans can continue to rotate for a while
after the disconnection of the electrical supply.
• Service the main circuit breaker once a year. If not serviced, damage can occur
to the wind turbine.
Note:
• Only authorized persons are allowed to repair a malfunctioning converter.
Safety instructions 13

Electrical safety in installation, start-up and maintenance
￭Precautions before electrical work
These instructions are for the qualified electricians who do work on the converter, generator
cable or generator.
WARNING!
Obey these instructions. If you ignore them, injury or death, or damage to the
equipment can occur. If you are not a qualified electrical professional, do not do
electrical installation or maintenance work. Do these steps before you do installation
or maintenance work.
1. Clearly identify the work location.
2. Disconnect all possible voltage sources.
•Open the main circuit breaker (Q1), disconnect, lock and attach a warning notice to
it. See section Opening and disconnecting the main circuit breaker (page 16).
•Open the charging circuit switch-disconnector (Q10). See section Disconnecting the
charging circuit from the main circuit (page 18).
•Open and lock out the auxiliary voltage switch-disconnector (Q2). See section
Disconnecting the auxiliary power supply (page 19).
•Disconnect any external dangerous voltages from the control circuits (such as relay
outputs).
•Open, disconnect and lock out the breaker of the grid transformer as the main circuit
breaker of the converter does not remove the voltage from the grid cable busbars
and some auxiliary circuits. Attach a warning notice to the disconnector.
•Lock the turbine rotor (and generator shaft).
•Open the safety switch between the generator-side converter and the generator (if
any).
•After you disconnect the converter, always wait for five minutes to let the intermediate
circuit capacitors discharge before you continue.
3. Protect any other energized parts in the work location against contact.
4. Take special precautions when close to bare conductors.
5. Measure that the installation is de-energized.
•Use a multimeter with an impedance of at least 1 Mohm.
•Make sure that the voltage between the converter grid cable terminals (L1, L2, L3)
and the grounding (PE) busbar is close to 0 V.
•Make sure that the voltage between the generator cable terminals (U2, V2, W2) and
the grounding (PE) busbar is close to 0 V.
•Make sure that the voltage between the DC bus and the grounding (PE) busbar is
close to 0 V.
WARNING!
If the measurement requires removal or disassembly of shrouding or other
cabinet structures, obey the local laws and regulations applicable to live
working (including – but not limited to – electric shock and arc protection).
14 Safety instructions
3

6. Install temporary grounding as required by the local regulations.
7. Ask the person in control of the electrical installation work for a permit to work.
￭Additional instructions and notes
WARNING!
Obey these instructions. If you ignore them, injury or death, or damage to the
equipment can occur.
•If you are not a qualified electrician, do not do electrical installation or
maintenance work.
•We do not recommend that you secure the cabinet by arc welding. If you have
to, obey the instructions in the converter hardware manual.
•Do not do insulation or voltage withstand tests on the converter or converter
modules.
•Control boards of the converter unit may be at the main circuit potential.
Dangerous voltages can be present between the control boards and the frame
of the converter unit when the main circuit voltage is on. It is critical that the
measuring instruments, such as an oscilloscope, are used with caution and
safety always as a priority. The fault tracing instructions give special mention
of cases in which measurements may be performed on the control boards, also
indicating the measuring method to be used.
Note:
•The generator cable terminals on the converter are at a dangerously high voltage
when the converter is connected to the grid, regardless of whether the generator
is running or not.
•The converter DC bus carries a dangerous voltage (over 500 V) when the
converter is connected to the grid or when the generator shaft is rotating.
•External wiring can supply dangerous voltages to the terminals of relay outputs.
WARNING!
Use a grounding wristband when you handle printed circuit boards. Do not touch
the boards unnecessarily. The boards contain components sensitive to electrostatic
discharge.
￭Fiber optic cables
WARNING!
Obey these instructions. If you ignore them, equipment malfunction and damage
to the fiber optic cables can occur.
•Handle the fiber optic cables with care.
•When you unplug the cables, always hold the connector, not the cable itself.
•Do not touch the ends of the fibers with bare hands as the ends are extremely
sensitive to dirt.
•Do not bend the fiber optic cables too tightly. The minimum allowed bend radius
is 35 mm (1.4 in).
Safety instructions 15

￭Opening and disconnecting the main circuit breaker
These instructions are for the qualified electricians who do work on the converter, generator
cable or generator.
WARNING!
If you are not a qualified electrician, do not proceed or do any installation or
maintenance work.
1. Undo the two fastening screws of the main circuit breaker (Q1) cover.
2. Open the cover.
3. Open the cover of the red push button.
4. Push the red push button (“Push OFF”).
5. Close both covers in front of the push buttons.
6. Lock the covers with a padlock. Put the key(s) in a safe place.
7. Make sure that the OPEN/CLOSED indicator shows OPEN.
8. Write your name, phone number and the date to the “Do not switch on. Men at work”
warning sign and hang the warning sign on the main circuit breaker.
16 Safety instructions
3

5
1
3
4
6
8
7
2
Safety instructions 17

￭Disconnecting the charging circuit from the main circuit
WARNING!
If you are not a qualified electrician, do not proceed.
1. Make sure that you have opened the main circuit breaker (Q1). See section Opening
and disconnecting the main circuit breaker (page 16).
2. In the upper part of the main circuit breaker cubicle, turn the charging circuit switch (Q10)
from ON position (2a) to the OFF position (2b).
3. Lock the charging circuit switch to the OFF position with a padlock. Stow the key(s) in
a safe place.
4. Write your name, phone number and the date to the “Do not switch on. Men at work”
warning sign and hang the warning sign to the charging circuit switch.
2a
3
3
2b
18 Safety instructions
3

￭Disconnecting the auxiliary power supply
WARNING!
If you are not a qualified electrician, do not proceed.
1. Make sure that you have opened the main circuit breaker (Q1). See section Opening
and disconnecting the main circuit breaker (page 16).
2. In the upper part of the main circuit breaker cubicle, turn the auxiliary power supply
switch (Q2) from ON position (2a) to the OFF position (2b).
3. Lock the switch Q2 to the OFF position with a padlock. Stow the key(s) in a safe place.
4. Write your name, phone number and the date to the “Do not switch on. Men at work”
warning sign and hang the warning sign to the switch Q2.
2a
2b
3
Safety instructions 19

￭Grounding
These instructions are intended for all who are responsible for the grounding of the converter.
WARNING!
Obey these instructions. If you ignore them, injury or death, or damage to the
equipment can occur, and electromagnetic interference can increase.
•If you are not a qualified electrician, do not do electrical installation or
maintenance work.
•Always ground the converter, the generator and adjoining equipment to ensure
personnel safety in all circumstances, and to reduce electromagnetic emission
and interference.
•Make sure that the conductivity of the grounding conductors is sufficient. See
the converter hardware manual. Obey the local regulations.
•In a multiple-converter installation, connect each converter separately to the
protective earth (PE).
Note:
•You can use power cable shields as grounding conductors only when their
conductivity is sufficient.
•As the normal touch current of the converter is higher than 3.5 mA AC or
10 mA DC, you must use a fixed protective earth connection. See standard
IEC/EN 61800-5-1, 4.3.5.5.2..
20 Safety instructions
3