ABB ACS880-87LC-3200A User manual

—
ABB WIND TURBINE CONVERTERS
ACS880-87LC-3200A/3200A-7 wind turbine
converters
Hardware manual

ACS880-87LC-3200A/3200A-7 wind
turbine converters
Hardware manual
Table of contents
1. Safety instructions
4. Mechanical installation
6. Electrical installation
3AXD50000721986 Rev A
EN
Original instructions
EFFECTIVE: 2021-07-13

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 .............................................................
16Fiber optic cables ...............................................................................
17Opening and disconnecting the main circuit breaker .....................................
19Disconnecting the charging circuit from the main circuit ..................................
20Disconnecting the auxiliary power supply ..................................................
21Grounding .......................................................................................
22Work 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 ..............................................
31Layout drawings ....................................................................................
33Overview of power and control connections ...................................................
34Circuit boards .......................................................................................
35Master - master converters ...................................................................
37BAMU board ........................................................................................
37Type designation labels ...........................................................................
38Type designation key ..............................................................................
39Basic code .......................................................................................
39Option codes (plus codes) ....................................................................
4 Mechanical installation
41Contents of this chapter ...........................................................................
41Safety instructions .................................................................................
42Checklist before mechanical installation ........................................................
43Moving the converter package ...................................................................
43Moving the converter package by fork-lift ...................................................
43Moving the converter on rollers ..............................................................
44Unpacking ...........................................................................................
Table of contents 5

44Lifting the converter ................................................................................
45Placing the converter ..............................................................................
46Fastening the cabinet to the floor ................................................................
46Internal cooling circuit .............................................................................
46Lifting the door .....................................................................................
47Miscellaneous ......................................................................................
47Cable duct in the floor below the cabinet ...................................................
47Electric welding .................................................................................
5 Planning the electrical installation
49Contents of this chapter ...........................................................................
49Selecting the grid disconnecting device ........................................................
50Checking the compatibility of the generator and the converter .............................
50Protecting the generator insulation and bearings ..........................................
51Selecting the power cables .......................................................................
51General rules ....................................................................................
51Sufficient conductivity of the protective conductor .........................................
52Typical power cable sizes .....................................................................
52CE cables ....................................................................................
52UL cables ....................................................................................
53Alternative power cable types ................................................................
53Power cable types for limited use ........................................................
53Not allowed power cable types ...........................................................
54Generator cable shield .....................................................................
54Single core vs multicore cables in grid cabling .............................................
54Additional US and Canada requirements ...................................................
55Conduit .......................................................................................
55Armored cable / shielded power cable ...................................................
55Selecting the control cables ......................................................................
55General rules ....................................................................................
56Relay cable ......................................................................................
57Routing the cables .................................................................................
58Control cable ducts .............................................................................
58Protecting the converter installation .............................................................
58Protecting the grid cable in short-circuit situations ........................................
58Protecting the generator and generator cable in short-circuit situations ...............
58Protecting the converter, generator cable and grid cable against thermal overload ...
58Protecting the converter against ground faults in the generator or generator cable ...
59Protecting the converter against ground faults in the converter or grid cable .........
59Implementing the emergency stop function ....................................................
59Implementing the grid fault ride-through function .............................................
59Supplying power for the auxiliary circuits .......................................................
59Using a safety switch between the converter and generator ................................
59Protecting the contacts of relay outputs ........................................................
6 Electrical installation
61Contents of this chapter ...........................................................................
61Checking the insulation of the assembly .......................................................
61Converter ........................................................................................
61Grid cable ........................................................................................
62Generator stator and generator cable .......................................................
6 Table of contents

62Connecting the grid cables .......................................................................
62Connection diagram ............................................................................
63Connection procedure .........................................................................
64Connecting the generator cables ................................................................
64Connection diagram ............................................................................
64Connection procedure .........................................................................
65Connecting the external power supply cable for the auxiliary circuit .......................
66Connecting the control cables ...................................................................
67Default I/O connection diagrams .............................................................
7 Installation checklist
69Contents of this chapter ...........................................................................
69Before you start ....................................................................................
70Checklist .............................................................................................
8 Maintenance
71Contents of this chapter ...........................................................................
71Maintenance intervals .............................................................................
73Maintenance timers and counters ...............................................................
73Power connections ................................................................................
73Tightening .......................................................................................
73Fans ..................................................................................................
74Replacing the cooling fan of the converter module ........................................
76Replacing the fans of the main breaker cubicle ............................................
77Replacing the cooling fan of the auxiliary control cubicle ................................
78Replacing the cooling fan of the LCL filter cubicle .........................................
79Fuses ................................................................................................
79Replacing the DC fuses .......................................................................
80Replacing the AC fuses .......................................................................
81Replacing the DC chopper fuses .............................................................
82Converter module ..................................................................................
82Replacing the converter module .............................................................
82Required tools ...............................................................................
88Capacitors ...........................................................................................
88BCU control unit ....................................................................................
88Replacing the memory unit ...................................................................
88Replacing the real-time clock battery ........................................................
88Replacing the SD/SDHC memory card .....................................................
89Replacement illustration .......................................................................
89Main circuit breaker ................................................................................
90UPS unit .............................................................................................
9 Technical data
91Contents of this chapter ...........................................................................
91Ratings ..............................................................................................
91Definitions .......................................................................................
92Derating ..........................................................................................
92Ambient temperature derating ............................................................
92Altitude derating .............................................................................
92Type equivalence table ............................................................................
Table of contents 7

92Fuses ................................................................................................
92Main circuit AC fuses ..........................................................................
93Main circuit DC fuses ..........................................................................
93Fuses for the voltage measurement board BAMU ........................................
93Dimensions, weights and free space requirements ...........................................
93Losses, cooling data and noise ..................................................................
93Internal cooling circuit data ...................................................................
93Terminal and lead-through data for the grid connection ......................................
94Tightening torques .............................................................................
94Terminal and lead-through data for the generator cables ....................................
95Grid specification ...................................................................................
95Requirements for the grid connection ...........................................................
95Generator connection data .......................................................................
95BCU control unit ....................................................................................
95Efficiency ............................................................................................
95Degree of protection ...............................................................................
96Environmental and corrosion classification ....................................................
97Ambient conditions ................................................................................
98Materials .............................................................................................
98Auxiliary circuit current consumption ............................................................
99Applicable standards ..............................................................................
99CE marking .........................................................................................
99Compliance with the European Low Voltage Directive ....................................
99Compliance with the European EMC Directive ............................................
99Compliance with the European Machinery Directive .........................................
100Regulatory Compliance Mark (RCM) ...........................................................
100EAC (Eurasian Conformity) marking ............................................................
100Compliance with EN 61800-3:2004/A1:2012 ..................................................
100Definitions .......................................................................................
100Category C4 .....................................................................................
101ETL marking ........................................................................................
102WEEE mark .........................................................................................
102Disclaimers .........................................................................................
102Generic disclaimer .............................................................................
102Cybersecurity disclaimer ......................................................................
10 BCU-x2 control unit
103Contents of this chapter ...........................................................................
103General ..............................................................................................
103BCU control unit ................................................................................
104Layout and connections ...........................................................................
106Connector data .....................................................................................
11 BCU-x5 control unit
109Contents of this chapter ...........................................................................
109General ..............................................................................................
109BCU control unit ................................................................................
110Layout and connections ...........................................................................
113Connector data .....................................................................................
8 Table of contents

12 Dimension drawings
115Contents of this chapter ...........................................................................
13 Cooling and heating
119Contents of this chapter ...........................................................................
119Hardware description ..............................................................................
119General ..........................................................................................
119Diagram of the internal cooling and heating circuit ........................................
121Planning the cooling system .....................................................................
121Connection to a customer cooling unit ......................................................
121General requirements ......................................................................
121Coolant temperature control ...............................................................
122Mechanical installation ............................................................................
122Connecting the internal cooling circuit to a customer cooling unit ......................
122Connecting the liquid pipes ................................................................
122Filling up and bleeding the internal cooling circuit ............................................
123Converters with a customer cooling unit ....................................................
124Draining the internal cooling circuit ..............................................................
125Specifications .......................................................................................
125Temperature limits ..............................................................................
126Pressure limits ..................................................................................
126Water quality ....................................................................................
126Freeze protection and corrosion inhibition ..................................................
126Coolant concentration ......................................................................
127Coolant mixture quality .....................................................................
127Approved coolants ..........................................................................
127Materials .........................................................................................
128Cold start ............................................................................................
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 17).
•Open the charging circuit switch-disconnector (Q10). See section Disconnecting the
charging circuit from the main circuit (page 19).
•Open and lock out the auxiliary voltage circuit breakers (Q2 and Q3). See section
Disconnecting the auxiliary power supply (page 20).
•Note the voltage sources from UPS: Open the circuit breaker F31.
•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.
14 Safety instructions
3

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).
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.
Safety instructions 15

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).
16 Safety instructions
3

￭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.
Safety instructions 17

5
1
3
4
6
8
7
2
18 Safety instructions
3

￭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 17).
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.

2b
2a
3
3
Safety instructions 19

￭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 17).
2. In the upper part of the main circuit breaker cubicle, turn the auxiliary voltage circuit
breakers (Q2 and Q3) from ON position (2a) to the OFF position (2b).
3. Lock the auxiliary voltage circuit breakers (Q2 and Q3) 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
20 Safety instructions
3