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ACS800-67LC wind turbine converters hardware manual

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Summary of Contents for ACS800-67LC

Page 1: ... ABB WIND TURBINE CONVERTERS ACS800 67LC wind turbine converters Hardware manual ...

Page 2: ...AUA0000059432 ACS800 grid side control program firmware manual 3AUA0000075077 ACS800 67 LC doubly fed induction generator control program firmware manual 3AUA0000071689 Option manuals ICU800 67LC incoming units C108 C109 hardware manual 3AUA0000071553 ABRU 0x DC choppers D150 and resistors D151 for ACS800 67LC 77LC 87LC wind turbine converters hardware manual 3AUA0000076494 Manuals and quick guide...

Page 3: ...manual ACS800 67LC wind turbine converters 3AUA0000058400 Rev C EN EFFECTIVE 2018 11 09 2018 ABB Oy All Rights Reserved 1 Safety instructions 4 Mechanical installation Table of contents 6 Electrical installation ...

Page 4: ......

Page 5: ...ization by frame size and option code 18 Quick installation commissioning and operation flowchart 19 Terms and abbreviations 20 3 Operation principle and hardware description What this chapter contains 23 Operation principle 23 Wind turbine system with low voltage stator 690 V 24 Wind turbine system with medium voltage stator 1000 V 24 Grid side and rotor side converters 25 Product overview 26 Lay...

Page 6: ... 47 Joining the liquid cooling unit to the converter cabinet 49 Connecting the liquid pipes 49 Miscellaneous 50 Cable duct in the floor below the cabinet 50 Electric welding 51 Lifting the door option C161 51 5 Planning the electrical installation What this chapter contains 53 Selecting the grid side disconnecting device disconnecting means 53 Checking the compatibility of the generator and conver...

Page 7: ...Auxiliary power supply for converter non UPS 65 Planning the installation of equipment connected to the rotor cable 66 Safety switches contactors connection boxes etc 66 Bypass connection 66 6 Electrical installation What this chapter contains 67 Checking the insulation of the assembly 67 Converter 67 Grid cable 67 Rotor and rotor cable 68 DC resistor and resistor cable 68 Option D150 68 Option D1...

Page 8: ...g DC fuses 102 Bussmann fuses 103 Mersen fuses 103 Replacing AC fuses option C111 104 Replacing the capacitor of the LCL filter 105 Replacing the temperature measurement sensor 106 Replacing the smoke detector 107 Replacing the main contactor 108 Replacing the charging circuit resistors 110 Replacing the crowbar 111 Replacing the crowbar resistor 112 9 The internal cooling circuit What this chapte...

Page 9: ...cooling circuit data 125 LCL filter data 125 Terminal and lead through data for the power cables 125 Terminal and lead through data for the control cables 126 Electric power network specification 127 Generator connection data 127 DC resistor connection data 128 DC connection data 128 Efficiency 128 Degree of protection 128 Ambient conditions 128 Materials 129 Auxiliary circuit current consumption ...

Page 10: ...95 0865 7 and 2035 1125 7 140 With 400 mm wide incoming cubicle option C111 141 Sealing modules for grid cables 142 Option 1H370 142 Options 1H370 and C111 142 Options 2H370 and C111 143 Option 1H371 143 Options 1H371 and C111 144 Options 2H371 and C111 144 Option H378 145 Options H378 and C111 145 Sealing modules for rotor cables 146 Option 1H372 146 Option 2H372 147 Option 3H372 148 Option 1H373...

Page 11: ...l warnings and notes Warnings caution you about conditions which can result in serious injury or death and or damage to the equipment and advise on how to avoid the danger Notes draw attention to a particular condition or fact or give information on a subject The warning symbols are used as follows Electricity warning warns of hazards from electricity which can cause physical injury and or damage ...

Page 12: ...that the converter does not have any live parts before beginning work Apply temporary grounding before working on the unit The converter does not have internal grounding device therefore external equipment is required Do not work on the control cables when input power is applied to the converter or to the external control circuits Externally supplied control circuits eg UPS may carry dangerous vol...

Page 13: ...e intended for all who are responsible for the grounding of the converter Incorrect grounding can cause physical injury death or equipment malfunction and increase electromagnetic interference WARNING 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 grounding conductors ...

Page 14: ...r damage to the equipment WARNING Beware of hot liquid Do not work on the liquid cooling system until the pressure is lowered down by stopping the pumps High pressure warm coolant 6 bar 600 kPa over 50 C 122 F is present in the internal cooling circuit when it is in operation Before power switch on make sure that the internal cooling circuit is filled up with appropriate coolant Running the pump d...

Page 15: ...e converter will start immediately after fault reset unless the converter is configured for a pulse start stop by a parameter WARNING Do not work on the converter when the generator is rotating Also when the input power is switched off and the converter is stopped a rotating generator may feed power to the intermediate circuit of the converter and the power connections become live Before installat...

Page 16: ...16 Safety instructions ...

Page 17: ...compatible with ACS800 67LC wind turbine converters Target audience This manual is intended for people who plan the installation install and service the converter Read the manual before working on the converter The reader of the manual is expected to know the standard electrical wiring practices electronic components and electrical schematic symbols The manual is written for readers worldwide Both...

Page 18: ...ctions The internal cooling circuit describes the cooling system of the converter Technical data contains the technical specifications of the converter eg ratings frame sizes and technical requirements and provisions for fulfilling the requirements for CE and other markings Dimension drawings contains dimension drawings of the converter Related documents See List of related manuals inside of the f...

Page 19: ... non operational for more than one year reform the converter DC link capacitors Contact your local ABB representative Only intact units may be started up Check the installation site Checking the installation site page 43 Route the cables Routing the cables page 62 Mount the cabinet line up Mechanical installation page 43 Connect the liquid cooling connections The internal cooling circuit page 113 ...

Page 20: ... the resistor when necessary The crowbar operates when the DC link voltage or rotor circuit current exceeds certain maximum limit The voltage rise is typically caused by grid failures like voltage dips sags Crowbar type ACBU is used in ACS800 67LC DC link DC circuit between grid side converter and rotor side converter DC link capacitors Energy storage which stabilizes the intermediate circuit DC v...

Page 21: ...nt for IGBT supply unit RMIO board NCAN CANopen Adapter Module NDCU Drive Control Unit Consists of a AMC board and NIOC board built into a metal housing NDCU unit controls the rotor side converter NDNA DeviceNet Adapter Module NETA Ethernet Adapter Module NIBA Interbus S Adapter Module NIOC Input Output Board Part of the NDCU Drive Control unit NPBA PROFIBUS DP Adapter Module NTAC Pulse Encoder In...

Page 22: ...22 Introduction to the manual ...

Page 23: ...DTC via power converter The rotor control is four quadrant allowing independent control of real and reactive power flow in either direction rotor to grid or grid to rotor or confined to unidirectional grid to rotor active power flow Induction generators have a gearbox for coupling the generator shaft to turbine hub active control of turbine blade pitch for maximizing production and controlling mec...

Page 24: ...ansformer Doubly fed induction generator WIND TURBINE CTRL Rotor bearing Pitch drive Gearbox Medium voltage switchgear Low voltage switchgears Wind turbine converter MCB EMERGENCY OPEN CTRL Rotor hub CONVERTER CTRL MCB CTRL MCB1 ON OFF CTRL MCB3 ON OFF CTRL Brake system Blades R2 ABRU R2 ACBU MCB3 LCL ISU MCB2 INU MCB CONVERTER CTRL Pitch drive Gearbox Turbine transformer High voltage switchgear W...

Page 25: ...t via a fiber optic link RDCU 12C control unit contains RDCO DDCS communication option module containing fiber optic terminals The grid side converter rectifies three phase AC current to direct current for the intermediate DC link of the converter The intermediate DC link supplies the rotor side converter The line filter suppresses the AC voltage and current harmonics As default the grid side conv...

Page 26: ...nted in the following drawings For power cabinet layout see ICU800 67LC incoming units C108 C109 hardware manual 3AUA0000071553 English No Description 1 Incoming cubicle ICU 2 LCL filter cubicle FIU 3 IGBT supply module cubicle ISU 4 Inverter module cubicle INU 5 Auxiliary control cubicle ACU Doors closed 1 2 3 4 5 ...

Page 27: ... of the crowbar 6 Module cooling fans 7 Auxiliary control unit cooling fan 8 Rotor side power cable terminals behind removable fans 9 PE terminal cabinet grounding busbar behind the coolant pipe 10 Sliding frame with control electronics 11 DC link fuses 12 Coolant inlet pipe 13 Coolant outlet pipe 14 Common mode filters 15 Crowbar in the swing out frame 16 Smoke detectors 17 Common mode filter of ...

Page 28: ... behind the swing out frame of the crowbar 8 Module cooling fans 9 Rotor side power cable terminals behind removable fans 10 PE terminal cabinet grounding busbar behind the coolant pipe 11 Sliding frame with control electronics 12 DC link fuses 13 Auxiliary control unit cooling fan 14 Coolant inlet pipe 15 Coolant outlet pipe 16 AC fuses 17 Common mode filters 18 Crowbar in the swing out frame 19 ...

Page 29: ...of the cubicle Each parallel module is connected to the inverter module cubicle internally by busbars The coolant enters the module at the bottom front and exits at the top Inside the module the coolant runs through the heatsink as well as an air to liquid heat exchanger For more information on the liquid cooling system see chapter The internal cooling circuit The cooling fan below the module forc...

Page 30: ...the converter to be connected to the grid even during very severe grid faults Crowbar is triggered if the DC link voltage is too high or alternatively if the rotor current is too high Active crowbar is controlled by the rotor side converter control program but in case of internal failure it can protect the converter independently Circuit diagram and layout of the crowbar is shown below Crowbar ACB...

Page 31: ...rol unit together with other hardwired faults for example LCL filter temperature Smoke detector alarm can be reset only with auxiliary power reboot If the converter is started when the smoke detector alarm is ON DI1 trip on the grid side converter will occur after 2 seconds In case of smoke detector alarm it is mandatory to check the converter for possible hardware related issues Especially LCL fi...

Page 32: ...of degree of protection UL Type 12 This includes power cables control cables user connections and 230 V AC supply cable Blank plate The blank plate has no openings for the cables when delivered Ensure that all the lead through components you use fulfill the requirements of degree of protection IP54 or higher Sealing modules The cables enter the cabinet through the sealing modules The number of sea...

Page 33: ...at the side of the cabinet Terminal Description X1 230 V AC supply non UPS X2 230 V AC supply UPS X3 Ethernet X4 Fieldbus X5 Safety circuit and control signals X6 1 External grid MCB control X6 2 External stator MCB control X7 Pulse encoder X8 1 Grid voltage measurement X8 2 Stator voltage measurement Marked with X80 when option G335 is selected X9 Stator current measurement X10 ICU auxiliaries Ma...

Page 34: ...rinciple and hardware description Circuit boards The diagram below shows the interconnections between the circuit boards of the converter For details see the circuit diagrams delivered with the converter or NUIM 10C ...

Page 35: ...ce DriveWindow PC tool is used with the ACS800 67LC Control unit of the grid side converter The grid side converter is controlled by its own RDCU control unit The RDCU is connected to the grid side converter power modules by a fiber optic link distributed through an APBU optical branching unit in case of parallel connected power modules In the grid side converter module s the fiber optic link is c...

Page 36: ...2 7 AI3 8 AI3 9 AO1 10 AO1 11 AO2 12 AO2 1 DI1 2 DI2 3 DI3 4 DI4 5 DI5 6 DI6 7 24 DV 8 24 DV 9 DGND 1 24 V 2 GND 3 24 V 4 GND 1 24 V 2 GND 1 R01 NC 2 R01 C 3 R01 NO 1 R02 NC 2 R02 C 3 R02 NO 1 R03 NC 2 R03 C 3 R03 NO 24 V OUT 200 mA RELAY OUTPUT 1 RELAY OUTPUT 2 RELAY OUTPUT 3 NDCU 32C DIGITAL INPUTS ANALOG INPUTS OUTPUTS 1 24 V 2 0 V 3 24 V 4 0 V AM32C RS 485 CONTROL PANEL 24 V IN X27 X26 X25 X23...

Page 37: ...cal link to AINT NINT board or branching unit RDCU 12C 64531476 PPCS COMMUNICATION CHANNEL U I MEASUREMENT NUIM 61C V41 V42 VOLTAGE AND CURRENT MEASUREMENT UNIT 1 POWER SUPPLY X7 2 3 4 5 6 15 V GND 15 V 24 V X2 1 IU A 2 GND X1 IW C 1 STATOR VOLTAGE MEASUREMENT U NOM 690 V X6 2 3 4 5 6 V B W C 7 U A 1 NET VOLTAGE MEASUREMENT GRID SUPPLY U NOM 690 V X5 2 3 4 5 6 V B W C 7 U A 1 2 GND VOLTAGE MEASURE...

Page 38: ...signation key 3 Valid markings 4 Ratings of the unit D D C S 1 0 M B d V 1 1 V 1 2 X 2 I U X 1 1 2 3 4 X 3 I V X 4 I W X 5 5 6 7 8 1 2 3 4 D D C S 5 M B d S 1 D D C S A D D R 1 0 1 F P W R O K F A U L T U V D C X 6 1 2 3 S 2 2 1 6 5 3 7 3 8 2 9 2 6 2 0 9 0 1 5 4 0 1 0 2 7 0 7 8 0 0 6 8 8 0 9 3 4 0 7 3 1 0 5 2 2 0 3 8 5 0 2 5 7 0 1 9 5 0 1 7 2 0 4 6 7 0 3 6 6 0 2 6 1 0 1 9 2 0 1 2 8 0 0 9 8 0 0 8 6...

Page 39: ...ed by online UPS auxiliary power connection 1 phase 50 60 Hz supply 230 VAC control voltage NTAC 02 NAMU 6x doubly fed induction generator control program Control logic for cabinet liquid circuit heater cooling connection with G2 thread cooling connection on the right hand side of the cabinet EMC 2nd Environment filter du dt limitation by choke common mode filter Emergency stop cat 0 ICU 200 mm wi...

Page 40: ...ble sealing module entry for 28 54 mm diameter single phase cables Power Cabinet As standard the power cabinet includes stator circuit breaker stator contactor s stator current measurement L1 and L3 bottom entry and exit of cables blank cable entry plate and AC fuses for grid side converter IP54 degree of protection For detailed description of power cabinet options see ICU800 67LC incoming units C...

Page 41: ...replaced by NUIM 10 for MV measurement stator voltage 1kV Fieldbus options K451 DeviceNet adapter NDNA 02 K453 Interbus S adapter NIBA 01 K454 PROFIBUS DP adapter NPBA 12 K457 CANopen adapter NCAN 02 Ethernet K464 Ethernet adapter EIP MB TCP NETA Specialities P902 Customized according to Technical Appendix P904 Extended warranty 24 30 P909 Extended warranty 36 42 P910 Service plan 48 54 P911 Servi...

Page 42: ...42 Operation principle and hardware description ...

Page 43: ...t vertical position For tilted installations contact your local ABB representative The floor that the unit is installed on must be of non flammable material as smooth as possible and strong enough to support the weight of the unit Anything located immediately next to the converter cabinet must be of non flammable material The floor flatness must be checked with a spirit level before installing the...

Page 44: ...cement if ordered lifting bars Following equipment are located in the floor of the inverter module cubicle fastening equipment kit for fastening the cabinet to the roof appropriate manuals and guides optional module manuals delivery specific circuit diagrams delivery specific dimensional drawings delivery specific test reports delivery documents Lead through frame and sealing modules if ordered ar...

Page 45: ...lifting bars If the lifting bars are removed the bolts must be refastened to retain the degree of protection of the cabinet by fork lift or pallet truck The centre of gravity is high Be therefore careful when transporting the unit Avoid tilting the cabinets The units are to be moved only in the upright position If using a pallet truck check its load capacity before attempting to move the unit Do n...

Page 46: ...dule replacement For more accurate space requirements for the door openings see chapter Dimension drawings Note 3 Leave 115 mm free space at the right or left hand side of the converter for the cooling pipe connections depending on which side the cooling connections are Note 4 Leave 150 mm free space at the right hand side for the plug in connectors Note 5 Height adjustment can be done by using me...

Page 47: ...stening the cabinet to the roof If the converter is installed in a nacelle the cabinet roof must be fixed to the nacelle structure for roof support Roof support kit is included in the delivery as standard The lifting lugs on the top of the cabinet are replaced with the roof support Support for both sides of the cabinet roof is required 2 View from side ...

Page 48: ...inet roof 68306931 E 2 1 Bolt the cabinet to the floor through the holes in each flat bar at the base of the cabinet using M10 or M12 screws 2 Remove the lifting bars 3 Fasten the top of the cabinet to the rear wall and or roof using the brackets delivered with the converter Gaskets and cork pads are included Use the lifting bar fastening holes and bolts Use the original bolts to block any unused ...

Page 49: ... cooling pipe connections between two separate units eg LCU and the converter connection Always use a flexible connector that can reduce possible stress caused by eg vibration 2 Check visually that the converter liquid pipes are not damaged threads and flange joint not damaged 3 Connect the external cooling circuit pipes to the LCU Secure the pipes mechanically See chapter Technical data for the p...

Page 50: ...r must carry The shaded area can be used for a cable duct Prevent the cooling air flow from the cable duct to the cabinet by bottom plates To ensure the degree of protection for the cabinet use the original bottom plates delivered with the unit With user defined cable entries take care of the degree of protection fire protection and EMC compliance Cables 50 mm 100 mm Front Front Minimum widths for...

Page 51: ...abinet within 0 5 metres of the welding point WARNING If the welding return wire is connected improperly the welding circuit may damage electronic circuits in the cabinet The thickness of the zinc coating of the cabinet frame is 100 to 200 micrometres on the flat bars the coating is approximately 20 micrometres Ensure that the welding fumes are not inhaled Lifting the door option C161 1 Open the h...

Page 52: ...52 Mechanical installation ...

Page 53: ...ing the grid side disconnecting device disconnecting means The converter must always be equipped with a grid side disconnecting device which can be locked to the open position for installation and maintenance work If the converter is equipped with the 400 mm wide incoming cubicle option C111 or power cabinet option C108 or C109 it is equipped with the disconnecting device automatically For the oth...

Page 54: ...this manual In addition insulated N end non drive end bearings must be used Selecting the power cables General rules Dimension the grid side and rotor side connection cables according to local regulations The cable must be able to carry the converter load current and withstand the voltage stress of the converter See chapter Technical data for the rated currents The cable must be rated for at least...

Page 55: ...d on UL508A and National Electric Code 2008 US Rotor side converter cables Type name Rotor side converter current rating A 240mm2 185mm2 120mm2 3 240mm2 120mm2 3 185mm2 95mm2 3 120mm2 70mm2 nr of cables phase nr of cables ACS800 67LC 1075 0575 7 898 2 3 4 3 3 4 ACS800 67LC 1375 0575 7 1143 3 4 5 3 4 5 ACS800 67LC 1375 1125 7 1143 3 4 5 3 4 5 ACS800 67LC 1595 0865 7 1334 4 4 6 4 5 6 ACS800 67LC 203...

Page 56: ...0 67LC 1375 0575 7 480 2 3 ACS800 67LC 1375 1125 7 941 5 6 ACS800 67LC 1595 0865 7 720 3 4 ACS800 67LC 2035 1125 7 941 5 6 Symmetrical shielded cable three phase conductors and a concentric or otherwise symmetrically constructed PE conductor and a shield Recommended PE conductor and shield Shield Shield A separate PE conductor is required if the conductivity of the cable shield is 50 of the conduc...

Page 57: ... North America 600 V AC cable is accepted up to 500 V AC 1000 V AC cable is required above 500 V AC below 600 V AC For converters rated over 100 A the power cables must be rated for 75 C 167 F Insulation jacket Copper wire screen Helix of copper tape Cable core Inner insulation U2 V2 W2 PE Converter U2 V2 W2 PE Converter K L M PE G 3 L1 L3 L2 Concentric Al Cu shield Single core cable shielded or u...

Page 58: ...mor cable with symmetrical grounds is available from the following suppliers trade names in parentheses Anixter Wire Cable Philsheath BICC General Corp Philsheath Rockbestos Co Gardex Oaknite CLX Shielded power cables are available from Belden Lapp Kabel ÖLFLEX and Pirelli among others Maximum ampere rating of overcurrent protection for field wiring conductors supplying panel Size of equipment gro...

Page 59: ...NE A system shown below is usually called the protective multiple earth PME system TN S power supply network In TN S power supply network earth terminal is connected by the supply protective conductor PE back to the star point neutral of the secondary winding of the supply transformer which is also connected at that point to an earth electrode The earth conductor usually takes the form of the armo...

Page 60: ...nverter L1 L2 L3 PE PE Wind turbine main earthing busbar 2 1 1 2 Not used if the supply cable screen operates as a protective conductor 1 As short as possible for low inductance L1 L3 L2 It is recommended to arrange the cables as shown alongside each other to achieve a current distribution as accurate as possible Gaps between cables are required for cooling L1 L3 L2 L1 L3 L2 L1 L3 L2 L1 L3 L2 N L1...

Page 61: ... insulated on the converter side The connection is represented below Selecting the rotor cabling principle Only use three phase symmetrical cables between the converter and the rotor For the possible rotor cable shield constructions see section Rotor cable shield on page 57 Rotor cable connections with parallel symmetrical cables are shown below For information on how to change the rotation direct...

Page 62: ... recommended that the relay controlled signals be run as twisted pairs Relay cable The cable type with braided metallic screen eg ÖLFLEX LAPPKABEL Germany has been tested and approved by ABB Control panel cable In remote use the cable connecting the control panel if any to the converter must not exceed 3 metres 10 ft The cable type tested and approved by ABB is used in control panel option kits Co...

Page 63: ... cable Grid cable Control cables min 300 mm 12 in Rotor cable Grid cable Converter min 200 mm 8 in 230 V 115 V 24 V 24 V 230 V 115 V Lead 24 V and 230 V 115 V control cables in separate ducts inside the cabinet Not allowed unless the 24 V cable is insulated for 230 V 115 V or insulated with an insulation sleeving for 230 V 115 V ...

Page 64: ...ncoming cubicle option C111 or a power cabinet option C108 or C109 For the other units the fuses must be acquired and installed outside the converter cabinet by the user WARNING Circuit breakers are not capable of providing sufficient protection because they are inherently slower than fuses Always use appropriate fuses DC fuses The converter employs fuses in the DC link between the grid side and r...

Page 65: ...ard the converter auxiliary circuit is to be supplied from the power supply network through an external auxiliary voltage transformer and UPS The converter is equipped with terminals for connecting external control voltages X1 and X2 The circuit breakers are located in the auxiliary control cubicle of the converter For information on the power consumption of auxiliary devices see section Auxiliary...

Page 66: ...all the equipment in a metal enclosure with 360 grounding for the shields of both the incoming and outgoing cables or connect the shields of the cables otherwise together US Install the equipment in a metal enclosure in a way that the conduit or rotor cable shielding runs consistently without breaks from the converter to the generator Bypass connection WARNING Never connect the power supply to the...

Page 67: ...instructions given in chapter Safety instructions Ignoring the instructions can cause physical injury or death or damage to the equipment Converter Every converter has been tested for insulation between the main circuit and the chassis at the factory 2700 V rms 50 Hz for 1 second Do not make any voltage tolerance or insulation resistance tests eg hi pot or megger on any part of the converter as te...

Page 68: ...sture inside the generator casing will reduce the insulation resistance If moisture is suspected dry the generator and repeat the measurement DC resistor and resistor cable Option D150 Check that the resistor cable is connected to the resistor and disconnected from the converter output terminals R and R At the converter end connect the R and R conductors of the resistor cable together Measure the ...

Page 69: ...w shows the connection of the grid cable to the converter The connection principle is the same also for the larger units Note See chapter Technical data for number and sizes of the cable lead throughs number and sizes of the connection busbars tightening torques for the power connections Note For the instructions on the possible construction and sizes of the grid side cabling and PE conductor see ...

Page 70: ...nism 2 Remove the shroud that protects the grid cable connection busbars and cable entries 3 Cut drill suitable holes for the cables Smooth the hole edges 4 Lead the cables inside the cabinet through the lead through plate holes Mind the edges 5 Seal the cable lead throughs to retain the degree of protection of the enclosure to keep the dust and humidity out of the cabinet 6 Connect the cables to ...

Page 71: ...ipment 1 Open the door of the incoming cubicle Unlock the handle release it from the holder and turn upwards to release the door locking mechanism 2 Remove the shroud that protects the cable connection busbars and cable entries 3 Remove the blank plate and the gasket under it 4 Follow the instructions below Fasten the gasket to the collar plate a Fasten the sealing module frame to the collar plate...

Page 72: ...two halves when held against the cable Lubricate all modules for the frame thoroughly on both the inside and the outside surfaces Mount the modules by sliding them in through the angled entry side of the frame Mount the modules row by row starting from the inside Precompress the frame Lubricate the compression units Insert one in the top of each opening Tighten all compression units alternately un...

Page 73: ...ubicle through the IP sealing glands Ground a shielded cable 360 at cabinet PE busbar lead through with an EMC cable gland to be supplied by the customer Connect the cables as follows Twist the cable shields into bundles and connect to cabinet PE ground busbar Connect any separate ground conductors or cables to cabinet PE ground busbar Connect the phase conductors to terminals L1 L2 and L3 Tighten...

Page 74: ...ysically identical considering cable type cross sectional area and length Connection diagram The diagram below shows the connection of the grid cable to the converter The connection principle is the same also for the larger units Connection procedure See pages 70 73 PE L1 L2 L3 K1 F1 Q1 Grid cable entry plate blank plate Grid cable connection terminals L1 L2 L3 ...

Page 75: ...m A connection diagram of frame 2 R8i parallel connected power modules feeding one generator is shown below The cable connection for frames 2 R8i and up is similar Note Rotor side cable connection terminals are U2 V2 W2 and PE To be wired by the user For selection of the cables see chapter Planning the electrical installation For the terminal sizes tightening torques and lead throughs see chapter ...

Page 76: ...ad throughs to retain the degree of protection of the enclosure to keep the dust and humidity out of the cabinet 7 Connect the cables to the appropriate busbars See section Connection diagram For the tightening torques see chapter Technical data Note Only use lead through components that fulfill the requirements of degree of protection IP54 or higher Connection procedure sealing modules at the cab...

Page 77: ...o bundles and connect to cabinet PE ground busbar Connect any separate ground conductors or cables to cabinet PE ground busbar Connect the phase conductors to terminals U2 V2 and W2 See the appropriate connection diagram above Tighten the phase conductors and PE to 70 N m 50 lbf ft torque When single core cables without metal shield are used Lead the cables into the inside of the cubicle through t...

Page 78: ...ternative 2 grounding the twisted shield 360 grounding of the shield Short pigtail EMC cable gland Conductive shielding and compression seal Cable shield As short unshielded wires as possible Note EMC cable glands are not included in the delivery They must be supplied by the customer Lead through plate L1 L2 L3 PE Cable lead through when shielded cable is used 6 ...

Page 79: ...Electrical installation 79 3 3 Rotor side cable connection terminals U2 V2 W2 ...

Page 80: ...X1 230 V AC supply non UPS Pin Description 3 L 4 N PE PE PE Connector X2 230 V AC supply UPS Pin Description 1 L 2 N PE PE PE Connector X4 fieldbus Fieldbus Pin Description CANopen 1 CAN_H 2 CAN_L 3 GND PROFIBUS DP 1 D N 2 D P DeviceNet 1 CAN_H 2 CAN_L 3 GND Connector X3 RJ45 cable with Ethernet 1 TD 2 TD 3 RD 4 NC 5 NC 6 RD 7 NC 8 NC Casing PE 2 ...

Page 81: ... s common fault B2 Normally open contact converter s common fault B3 Normally closed contact converter s common fault B4 230 V AC release blocking of grid MCB inside ABB converter switching on B5 0 V AC release blocking of grid MCB inside ABB converter switching on C1 Common request for immediate grid MCB outside of ABB converter switching off C2 Emergency stop reset contact C3 Emergency stop rese...

Page 82: ... your converter from the circuit diagrams delivered with the converter Connector X7 pulse encoder Pin Description A1 CHA B1 CHA C1 Shield A2 CHB B2 CHB C2 Shield A3 CHZ B3 CHZ C3 Shield A4 0 V B4 V out C4 Shield C5 Outer shield Connector X6 2 Stator MCB control Pin Description 1 0 V DC 2 Not used 3 Not used 4 UPS supply voltage 5 Not used 6 Not used 7 Not used 8 Not used 9 0 V 10 Springs charging ...

Page 83: ...grams delivered with the converter Connector X8 1 Grid voltage measurement Pin Description 3 Phase U 5 Phase V 7 Phase W 10 Not used 12 Not used 14 Not used Connector X8 2 Stator voltage measurement Pin Description 3 Not used 5 Not used 7 Not used 10 Phase U 12 Phase V 14 Phase W Connector X9 Stator current measurement Pin Description 1 Phase U S1 2 Phase U S2 3 Phase W S1 4 Phase W S2 ...

Page 84: ...sor 4 High temperature sensor 5 Low temperature sensor 6 Low temperature sensor 7 Main fuses status contact 8 Main fuses status contact 9 230 V AC fan supply voltage 10 0 V AC fan supply voltage Connector X11 Grid MCB trip and on off status and Interbus option K453 Pin Description A1 NOT DI1 option K453 A2 DI2 option K453 A3 NOT DO1 option K453 A4 DO1 option K453 A5 DG1 option K453 B1 Common grid ...

Page 85: ...y instructions Ignoring the instructions can cause physical injury or death or damage to the equipment Connecting to the grid side converter Connect a PC to CH3 of the RDCO module via a fiber optic link RDCO is attached to the option slot 3 of the RDCU unit If NETA module option K464 is connected remove its fiber optic link first Connecting to the rotor side converter Connect a PC to CH3 of the ND...

Page 86: ...rs as follows Run the fiber optic cables to the inside of the auxiliary control cubicle Connect one wire to the RDCU unit channel CH3 and the other fiber optic cable to the NDCU unit of the converter cubicle For the connectors of the RDCU and NDCU units see section Control unit NDCU 33Cx RDCU 12C on page 36 To push the sliding frame back into the cubicle 1 Press down the knob on the back of the un...

Page 87: ...l installation See chapters Planning the electrical installation Electrical installation The converter has been fixed properly to floor and if necessary due to vibration etc also from top to the wall or roof The ambient operating conditions are within the allowed limits See chapter Technical data If the lifting bars have been removed ensure that the bolts are re fastened to retain the cabinet degr...

Page 88: ... D150 D151 have been connected to appropriate terminals R and R and the terminals have been tightened pull conductors to check The rotor cable is routed away from other cables The generator cable and DC resistor cable if present has been routed away from other cables No power factor compensation capacitors are connected to the rotor terminals The external control cables have been connected to appr...

Page 89: ...ices and Maintenance and Field Services Interval Maintenance action Instruction Every year of storage Capacitor reforming See Capacitors Every year Smoke detector inspection visual inspection and maintenance action if needed Inspect the smoke detector with test gas Every 2 years Addition of corrosion inhibitor to coolant Add inhibitor according to instructions For amount and type see chapter The i...

Page 90: ...es of the quick connector and apply a layer of suitable joint compound eg Isoflex Topas NB 52 from Klüber Lubrication onto them 4 Repeat steps 1 to 3 for all remaining modules Fans The cooling fan lifespan depends on the running time of the fan ambient temperature and dust concentration Each power module has own cooling fan Replacements are available from ABB Do not use other than ABB specified sp...

Page 91: ...n and maintenance page 12 have been taken into consideration 2 Disconnect the 230 V AC supply cables from connectors X1 and X2 at the right hand side of the cabinet 3 Open the door and remove the lower shroud metal grating of the cubicle 4 Disconnect the plug 5 Undo the two fastening screws of the fan 6 Pull the fan out 7 Install a new fan in reverse order ...

Page 92: ...92 Maintenance 4 6 5 5 ...

Page 93: ...er precautions described in section Safety in installation and maintenance page 12 have been taken into consideration 2 Disconnect the 230 V AC supply cables from connectors X1 and X2 at the right side of the cabinet 3 Open the door and remove the upper shroud of the cubicle by removing four screws 4 Disconnect the plug 5 Loosen the two fastening screws of the fan 6 Pull the fan out Remove the two...

Page 94: ...ns described in section Safety in installation and maintenance page 12 have been taken into consideration 2 Disconnect the 230 V AC supply cables from connectors X1 and X2 at the right side of the cabinet 3 Open the door and pull the sliding frame out of the cubicle For instructions see page 86 4 Disconnect the plug 5 Undo the two fastening screws of the fan 6 Pull the fan out Remove the two screw...

Page 95: ...from the module Unscrew the locking nut until fully open and pull the pipe out WARNING When re attaching the coolant hoses do not overtighten the outer nuts of the union leave 2 3 mm 0 08 0 1 in of thread visible Overtightening will break the hose 7 Unplug the fiber optic cables from the module 8 Disconnect the DC output busbars from the module Beware not to drop the screws inside the module 9 Rem...

Page 96: ...able joint compound eg Isoflex Topas NB 52 from Klüber Lubrication onto them 16 Install a new module in reverse order WARNING Mind your fingers when pushing the module into the wind turbine converter Do not place your fingers on the sides of the module when pushing ...

Page 97: ...Maintenance 97 6 Decoupling the pipes 6 6 7 Unplugging the fiber optic cables 9 Removing the mounting screws 7 9 9 9 9 13 Attaching the lifting chains ...

Page 98: ...n the module frame 2 Align the stand and the rails on which the module lies on Fasten the two screws removed in previous step back to their original positions Ensure that the legs lock into position WARNING When replacing the module note that the module is heavy and its center of gravity is high The module topples over easily 1 2 ...

Page 99: ...not possible to predict capacitor failure Capacitor failure is usually followed by damage to the unit and an input cable fuse failure or a fault trip Contact ABB if capacitor failure is suspected Reform re age spare part capacitors once a year according to Converter modules with electrolytic DC capacitors in the DC link Capacitor reforming instructions 3BFE64059629 English available through your l...

Page 100: ...ions described in section Safety in installation and maintenance page 12 have been taken into consideration 2 Disconnect the 230 V AC 115 V AC supply cables from connectors X1 and X2 at the right hand side of the cabinet 3 The APBU unit s are located in the auxiliary control cubicle see page 33 The grid side converter APBU unit is located under the RDCU unit Open the screws on the unit cover 3 pcs...

Page 101: ...r damage to the equipment 1 Open the connector and disconnect it from the pressure transmitter 2 Remove the pressure transmitter The coolant circulation stops automatically 3 Install a new pressure transmitter in reverse order Note When connecting the connector to the pressure transmitter make sure that the notch in the connector meets its counterpart in the pressure transmitter 1 2 3 ...

Page 102: ...er is disconnected from the power supply network and all other precautions described in section Safety in installation and maintenance page 12 have been taken into consideration 2 Remove the shrouds in front of the fuses 3 Open the M12 nuts and remove the fuses 4 If necessary adjust the assembly parts See sections Bussmann fuses and Mersen fuses 5 Insert new fuses 6 Re assemble the parts in revers...

Page 103: ...Maintenance 103 Bussmann fuses Mersen fuses ...

Page 104: ...lation and maintenance page 12 have been taken into consideration 2 Remove the shrouds in front of the fuses 3 Open the nuts and disconnect the microswitches Remove the fuses 4 Insert new fuses and connect the microswitches 5 Re assemble the parts in reverse order The tightening torque for the M12 nuts is 50 N m 37 lbf ft The tightening torque for the M8 nuts is 20 N m 15 lbf ft 2 3 ...

Page 105: ...aintenance page 12 have been taken into consideration 2 Remove the shroud of the LCL filter cubicle 3 Remove the four screws in front a four screws below b and two screws on top c of the capacitor 4 Remove the three busbar connection bolts and pull out the capacitor 5 Insert new capacitor 6 Re assemble the parts in reverse order Tightening torque for busbar connection bolts is 18 N m 13 lbf ft 2 3...

Page 106: ...er precautions described in section Safety in installation and maintenance page 12 have been taken into consideration 2 The temperature measurement sensors are located on the coolant inlet and outlet pipes in the cubicle the pipes enter the converter cabinet To detach the sensor turn the sensor left 3 To install a new sensor turn the sensor right ...

Page 107: ... section Safety in installation and maintenance page 12 have been taken into consideration 2 Remove the shrouds in front of the fuses 3 Turn the smoke detector to the left and remove the two fastening screws 4 Insert new smoke detector 5 Re assemble the parts in reverse order Inverter and supply module cubicles 400 mm wide incoming cubicle option C111 2 3 3 ...

Page 108: ... shroud of the LCL filter cubicle 3 Remove the ten fastening screws 4 Remove the four fastening screws and nine screws in the upper part of the cubicle 5 Remove the two nuts and one screw 6 Remove the three fastening screws and five screws in the front part of the cubicle 7 Remove the two screws in the main contactor 8 Pull the main contactor out and turn it 90 upwards simultaneously 9 Insert new ...

Page 109: ...Maintenance 109 5 6 7 ...

Page 110: ...ion Safety in installation and maintenance page 12 have been taken into consideration 2 Remove the shrouds in front of the resistors The resistor are located in the upper part of the cubicle 3 Remove the five fastening screws of the resistors 4 Unplug the resistor cable 5 Remove the six fastening screws 6 Insert new resistors 7 Re assemble the parts in reverse order 3 2 4 5 ...

Page 111: ...e four screws that fasten the swing out frame to the cabinet frame 4 Loosen the two panel screws of the hinge and pull out the swing out frame 5 Remove the crowbar cover by removing four panel screws 6 Remove the resistor cover by removing four M8 nuts and six M5 screws 7 Remove the resistor busbars 2 pcs 8 Remove AC and DC cables fasteners and other wires 9 Remove the crowbar from the swing out f...

Page 112: ...e parts remain hot for a while after the disconnection of input power 1 Follow the steps 1 8 in section Replacing the crowbar on page 111 2 Remove the crowbar resistor from the swing out frame by removing four M8 nuts 3 Insert new resistor 4 Re assemble the parts in reverse order 2 ...

Page 113: ...ts of two circuits firstly the internal cooling circuit that covers the heat generating electrical components and transfers the heat to the cooling unit and the external cooling circuit that is usually part of a larger external cooling system This chapter deals with the internal cooling circuit Liquid cooling unit is not included in the ABB deliveries the liquid cooling system of the converter doe...

Page 114: ...ooling unit General requirements Equip the system with an expansion tank to damp pressure rise due to volume changes when the temperature varies Keep the pressure within the limits specified in Specifications below Install a pressure regulator to ensure that the maximum permissible operating pressure is not exceeded Install a bleed valve at the highest point of the cooling circuit Install a drain ...

Page 115: ... humidity The following diagram shows an example of coolant temperature control using the three way valve in the external cooling circuit Part of the infeed coolant flow is directed into the return pipe through a three way valve without letting it circulate in heat exchanger if the coolant in the internal circuit is too cold Mechanical installation Coupling the internal cooling circuit to a custom...

Page 116: ...ntion to filling up and bleeding the pumps properly as they may be damaged if operated when dry Draining liquid into the sewer system is not allowed it may contain harmful substances like propylene glycol 1 Open the main bleed valve at the cooling unit 2 Open the inlet outlet and bleed valves of one converter cubicle 3 Lead the bleed hoses into buckets or other suitable containers Extend the stand...

Page 117: ...that contains eg propylene glycol into the sewer system is not allowed 2 Open the bleed valves to let air displace the liquid 3 If required dry the piping with compressed oil free air of less than 600 kPa 6 bar 4 If the converter is to be stored in temperatures below 0 C 32 F dry the cooling circuit with air fill the cooling circuit with a mixture of water corrosion inhibitor and antifreeze accord...

Page 118: ... measuring point must stay within the range of 120 kPa 380 kPa 1 2 3 8 bar for the converter to operate Tair C Min Tcoolant C φ 95 φ 80 φ 65 φ 50 φ 40 5 5 0 5 0 5 0 5 0 5 0 10 9 2 6 7 5 0 5 0 5 0 15 14 2 11 5 8 4 5 0 5 0 20 19 2 16 5 13 2 9 4 6 0 25 24 1 21 4 17 9 13 8 10 5 30 29 1 26 2 22 7 18 4 15 0 35 34 1 31 1 27 4 23 0 19 4 40 39 0 35 9 32 2 27 6 23 8 45 44 0 40 8 36 8 32 1 28 2 50 49 0 45 6 ...

Page 119: ...ght percentage according to ambient storage temperature T WARNING Operation at temperatures below 5 C 41 F is not permitted even with antifreeze Note If more than 25 is added the pressure loss in the system increases An operating pressure of more than 150 kPa is required for sufficient flow Tap water The use of tap water is allowed as follows Tap water must fulfil the requirements of the Council D...

Page 120: ...AISI 316L UNS 31603 heavy gauge aluminum plastic materials such as PA PEX and PTFE Note PVC hoses are not suitable for use with antifreeze rubber gasketing NBR nitrile rubber WARNING If connecting external piping to the internal cooling circuit use only materials that are specified above Copper and brass must not be used under any circumstances Even minor dissolution of copper can cause copper pre...

Page 121: ...or the converter with 50 Hz and 690 V AC power supply network are given below Grid side converter ratings For information on reactive power capability see ACS800 67LC system description and start up guide 3AUA0000059432 English ACS800 204LC Frame size Nominal ratings Icont max A AC Scont max kVA Qcont max kVAr Imax A AC Three phase supply voltage 525 690 V 0575 7 E205 R8i 480 574 470 718 0865 7 E2...

Page 122: ...e derating At altitudes from 1000 to 4000 m 3281 to 13123 ft above sea level the derating is 1 for every 100 m 328 ft If the installation site is higher than 2000 m 6600 ft above sea level contact the local ABB representative ACS800 104LC Frame size Nominal ratings Light overload use Heavy duty use Icont max A AC Scont max kVA Imax A AC IN A Ihd A Three phase supply voltage 690 V 1075 7 2 R8i 898 ...

Page 123: ...0M6467 3AUA0000062487 ACS800 67LC 1595 0865 7 1250 170M6466 3AUA0000062488 ACS800 67LC 2035 1125 7 1400 170M6467 3AUA0000062487 Type In A Mersen type MRP code Microswitch for the fuse MRP code ACS800 67LC 1075 0575 7 700 PC31UD69V700TF 3AUA0000081747 MS3 V1 5 3AUA0000081746 ACS800 67LC 1375 0575 7 700 PC31UD69V700TF 3AUA0000081747 ACS800 67LC 1375 1125 7 1400 PC33UD69V1400TF 3AUA0000081748 ACS800 ...

Page 124: ... mm option C111 wide incoming cubicle 2 With power cabinet option C108 or C109 3 With DC chopper option D150 4 With 400 mm wide incoming cubicle option C111 and DC chopper option D150 5 With power cabinet option C108 or C109 and DC chopper option D150 Type Height mm Depth mm Width mm ICU 200 mm ICU 400 mm C111 ACS800 67LC 1075 0575 7 2000 644 1600 1800 ACS800 67LC 1375 0575 7 2000 644 1600 1800 AC...

Page 125: ... C111 With option C108 or C109 With option D150 With options D150 and C111 With options D150 and C108 or C109 1075 0575 7 11 12 13 11 12 13 1375 0575 7 11 12 13 11 12 13 1375 1125 7 14 15 16 14 15 16 1595 0865 7 16 17 19 16 18 19 2035 1125 7 16 17 19 16 18 19 ACS800 67LC LCL filter L1 L2 C Type code MRP code Inductance uH MRP code Inductance uH MRP code Capacitance uF MRP code 1075 0575 7 ALCL 15L...

Page 126: ...female 09 33 000 6205 15 Han 10A Hood 19 20 010 1440 1 Cable gland M20 1 X7 Han 15D Crimp terminal Male insert M 09 21 015 3001 1 Han 0 5 mm2 Crimp contact male 09 15 000 6103 15 Han 10A Hood 19 20 010 1440 1 Cable gland M20 1 X10 Han 10A Crimp terminal Male insert M 09 20 010 3001 1 Han 1 0 mm2 Crimp contact male 09 33 000 6105 8 Han 2 5 mm2 Crimp contact male 09 33 000 6102 2 Han 10A Hood 19 20 ...

Page 127: ...hort circuit current is 65 kA when protected by fuses given under Fuses Short circuit current protection UL 508A US and Canada The converter is suitable for use on a circuit capable of delivering not more than 65 000 rms symmetrical amperes at 600 V maximum when protected by fuses given under Fuses Power factor 1 00 in normal use Harmonic distortion Harmonics below are the limits defined in IEEE51...

Page 128: ...rotective package Installation site altitude 0 to 2000 m 6562 ft above sea level Above 1000 m 3281 ft see section Derating on page 122 Air temperature 30 to 55 C 22 to 131 F Above 45 C 113 F see section Derating on page 122 No frost allowed Note UL temperature requirement max 40 C 104 F 40 to 70 C 40 to 158 F 40 to 70 C 40 to 158 F Water temperature See section Temperature limits on page 117 Relat...

Page 129: ...kness approx 80 µm on visible surfaces except back panel Colour RAL 7035 light beige semigloss Busbars Tin or silver plated copper Internal cooling circuit piping Aluminium acid fast stainless steel PA pipes Fire safety of materials IEC 60332 1 Insulating materials and non metallic items Mostly self extinctive Packaging Frame Wood or plywood Plastic wrapping PE LD Bands PP or steel Disposal The co...

Page 130: ...below The compliance with the European Low Voltage Directive is verified according to standards EN 61800 5 1 and EN 60204 1 IEC EN 60204 1 2006 Safety of machinery Electrical equipment of machines Part 1 General requirements Provisions for compliance The final assembler of the machine is responsible for installing an emergency stop device IEC EN 60529 2001 Degrees of protection provided by enclosu...

Page 131: ...Technical data 131 Declaration of incorporation ...

Page 132: ...l be logged into the logbook Compliance with the EN 61800 3 The EMC Directive defines the requirements for immunity and emissions of electrical equipment used within the European Union The EMC product standard EN 61800 3 covers requirements stated for converters Definitions EMC stands for Electromagnetic Compatibility It is the ability of electrical electronic equipment to operate without problems...

Page 133: ... category C4 is not intended to be used on a low voltage public network which supplies domestic premises Radio frequency interference is expected if the converter is used on such a network UL marking The converter is cULus listed industrial control panel The approvals are valid with rated voltages up to 600 V AC The markings are attached to the converter when option C129 cULus is selected ETL mark...

Page 134: ...anual for setting Default setting is off must be activated at start up DC chopper brake unit The converter can be equipped with a chopper unit that will allow the converter to dissipate regenerative energy normally associated with quickly decelerating a generator UL standards See section Applicable standards CSA marking ACS800 multidrive modules The module is cCSAus certified The approvals are val...

Page 135: ... lead through drawings are included The example drawing set helps in understanding the structure of the converter WARNING These drawings are not intended for mechanical installation and cable lead through purposes as they most probably differ from a customized converter The customer specific drawings are included in the delivery ...

Page 136: ...136 Dimension drawings ACS800 67LC 1075 0575 7 and 1375 0575 7 ...

Page 137: ...Dimension drawings 137 With 400 mm wide incoming cubicle option C111 ...

Page 138: ...138 Dimension drawings ACS800 67LC 1375 1125 7 ...

Page 139: ...Dimension drawings 139 With 400 mm wide incoming cubicle option C111 ...

Page 140: ...140 Dimension drawings ACS800 67LC 1595 0865 7 and 2035 1125 7 ...

Page 141: ...Dimension drawings 141 With 400 mm wide incoming cubicle option C111 ...

Page 142: ...n drawings Sealing modules for grid cables Dimensions and illustrations for optional sealing modules in incoming cubicles widths 200 mm and 400 mm option C111 are presented below Option 1H370 Options 1H370 and C111 ...

Page 143: ...Dimension drawings 143 Options 2H370 and C111 Option 1H371 ...

Page 144: ...144 Dimension drawings Options 1H371 and C111 Options 2H371 and C111 ...

Page 145: ...Dimension drawings 145 Option H378 Options H378 and C111 ...

Page 146: ...146 Dimension drawings Sealing modules for rotor cables Dimensions and illustrations for optional sealing modules in inverter module cubicles widths 500 mm and 700 mm are presented below Option 1H372 ...

Page 147: ...Dimension drawings 147 Option 2H372 ...

Page 148: ...148 Dimension drawings Option 3H372 ...

Page 149: ...Dimension drawings 149 Option 1H373 ...

Page 150: ...150 Dimension drawings Option 2H373 ...

Page 151: ...Dimension drawings 151 Option 3H373 ...

Page 152: ...152 Dimension drawings Option H375 ...

Page 153: ...umber of the unit in question A listing of ABB sales support and service contacts can be found by navigating to abb com searchchannels Product training For information on ABB product training navigate to new abb com service training Providing feedback on ABB Drives manuals Your comments on our manuals are welcome Navigate to new abb com drives manuals feedback form ...

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