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ABB ACS880-77CC, Hardware Manual

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BCU-x2 control unit

Contents of this chapter

This chapter describes the layout and connections of the BCU-x2 control unit and contains
the specifications of the inputs and outputs of the control unit.

For the actual connections of the control units used in the ACS880-77CC converter, see
the circuit diagrams delivered with the converter.

General

￭

BCU control unit

The BCU control unit consists of a BCON control board (and a BIOC I/O and power supply
board) built in a metal housing. The BCU is mounted separately from the converter module(s),
and connected to the module(s) by fiber optic cables. In this manual, the name “BCU-x2”
represents the control unit types BCU-12/-22.

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BCU-x2 control unit 99

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Summary of Contents for ACS880-77CC

Page 1: ...ABB WIND TURBINE CONVERTERS ACS880 77CC wind turbine converters Hardware manual...

Page 2: ......

Page 3: ...77CC wind turbine converters Hardware manual Table of contents 1 Safety instructions 4 Mechanical installation 6 Electrical installation 3AXD50000813605 Rev A EN Original instructions EFFECTIVE 2021...

Page 4: ......

Page 5: ...get audience 23 Categorization by frame size and option code 24 Quick installation commissioning and operation flowchart 25 Terms and abbreviations 26 Related documents 3 Operation principle and hardw...

Page 6: ...nal US and Canada requirements 55 Conduit 55 Armored cable shielded power cable 55 Selecting the control cables 55 General rules 56 Relay cable 56 Routing the cables 57 Control cable ducts 57 Protecti...

Page 7: ...er connections 72 Tightening 72 Fans 72 Replacing the cooling fan of the converter module 74 Replacing the fan of the main breaker cubicle 75 Replacing the cooling fan of the auxiliary control cubicle...

Page 8: ...93 Ambient conditions 94 Materials 94 Auxiliary circuit current consumption 95 Applicable standards 95 CE marking 95 Compliance with the European Low Voltage Directive 95 Compliance with the European...

Page 9: ...id pipes 118 Filling up and bleeding the internal cooling circuit 119 Converters with a customer cooling unit 120 Draining the internal cooling circuit 120 Cooling station control 121 Specifications 1...

Page 10: ...10...

Page 11: ...use 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 thes...

Page 12: ...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...

Page 13: ...cuum 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...

Page 14: ...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...

Page 15: ...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 h...

Page 16: ...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 L...

Page 17: ...5 1 3 4 6 8 7 2 Safety instructions 17...

Page 18: ...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 po...

Page 19: ...n 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 p...

Page 20: ...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 manu...

Page 21: ...is filled up with coolant Running the external cooling pump dry will damage it Also the converter will not cool down Avoid skin contact with coolant especially antifreeze Do not syphon them by mouth I...

Page 22: ...22...

Page 23: ...expected to know the fundamentals of electricity wiring electrical components and electrical schematic symbols The manual is written for readers worldwide Categorization by frame size and option code...

Page 24: ...sary option modules and equipment are present and correct Only intact converters may be started up Checklist before mechanical installation page 42 Check the installation site Routing the cables page...

Page 25: ...Optional CANopen adapter module FCAN Optional ControlNet adapter module FCNA Optional DeviceNet adapter module FDNA Optional I O extension adapter FEA 03 Optional HTL incremental encoder interface mod...

Page 26: ...40787 Emergency stop stop category 0 option Q951 for ACS880 77LC 87LC 87CC wind turbine converters user s manual 3AUA0000094606 Drive composer start up and maintenance PC tool user s manual Manuals an...

Page 27: ...manent magnet generator The converter is connected between the generator stator and the grid The converter can be installed up in the nacelle or down on the ground level The converter consists of cubi...

Page 28: ...ntermediate DC circuit The generator control is based on the Direct torque control DTC method Two phase currents and intermediate DC circuit voltage are measured and used for the control The third pha...

Page 29: ...KAN A 0HbL EK0E AE L 582F2 6 5DDF 7 582F2 6 5DDF 7 5D 5DDF 7 23D54 54D54 33 42 3 123 0456 23 X 3 6 4 6 F23 0 33 42 3 9 7 4 4 4 NTRA0NAHLH NH0E AE L H 4 4 4 4 4 NTRA0NAHLH NH0E AE L H 6_ a 5 4 Y 6 4 63...

Page 30: ...V2 W2 7 Output contactors optional 8 Generator side converter modules 9 Generator side converter DC fuses 10 Grid side converter modules 11 Grid side converter DC fuses 12 Grid side converter AC fuse...

Page 31: ...the auxiliary control cubicle 24 Optional heater for cold environment 25 Coolant connection of the cooling unit inlet pipe 26 Coolant connection of the cooling unit outlet pipe 27 Operation principle...

Page 32: ...d communication Master BCON CH0 CH1 CH2 CH3 BCON CH0 CH3 L1 L2 L3 U2 V2 W2 PSL PSL FXXX XCAN S500 CI581 CN S500 AX522 1 2 3 4 6 7 1 2 5 Description No Slots 1 3 1 RDCO slot 4 2 BCU x5 control unit 3 B...

Page 33: ...0 CI581 CN S500 AX522 1 3 5 6 4 CH0 CH1 CH2 CH3 2 Description No Slots 1 3 1 RDCO slot 4 2 BCU x5 control unit 3 External control via Ethernet 4 Grid side converter 5 Generator side converter 6 Operat...

Page 34: ...E M L 0 A 0EL GB 50FU 0E M L 0 A 50FU 093 D 0GOHHL 0E M L 0 A D 0GOHHL 093 IBMZB E 0 H 0 A IBMZB E 0 H U M0E UE MG0 HB 0G U OG 0 A9HB 50L _0 BIH 0 A4BIH 0L _ U 0H _BM0GOHHLKBG 0 A9 P 5 07 8 3 JBM B 0E...

Page 35: ...HLKBG 0 A9 P 5 07 8 3 JBM B 0EU LB 8 JBM B 0E BE K 0FM I0IUG BM0EU K B 3 8 2X 30 5 2 3 2 T 2 T 9 T 9 T 9 9 9 9 9 9 9 9 2 2 2 2 2 2 2 UHUEK M0EJUMZK Z 0 A JUMZK Z 0GHMK Z0I M 0 A JUMZK Z LUCB0FUOL 0 A3...

Page 36: ...markings type code and serial number of the converter Each converter module is also individually labeled Typical labels are shown below 1 2 5 6 7 4 1 2 5 6 7 4 3 3 3200 A 3200 A Description No Serial...

Page 37: ...ng location 6 Information about cooling IP class etc 7 Type designation key The type code of the wind turbine converter contains information on the specifications and configuration The first 23 digits...

Page 38: ...nnections on the right side C143 Cooling connections on the left side C144 Flange for cooling liquid connections of size DN64 with flange clamp ISO 6162 1 2002 C171 Grid control options Grid fault rid...

Page 39: ...V AC input L507 DDCS communication 1 L508 DDCS communication 2 L509 Safety Emergency Stop Category 0 Q951 Documentation language delivered set may include documents in English English R700 Specialiti...

Page 40: ...40...

Page 41: ...installation Contents of this chapter This chapter describes the mechanical installation procedure of the wind turbine converter Safety instructions See the safety instructions 4 Mechanical installat...

Page 42: ...ron bar and piece of planked wood Pozidriv and Torx 2 5 6 mm 0 98 0 2 in screwdrivers for the tightening of the frame screws Screws needed for fastening the cabling boxes and other accessories deliver...

Page 43: ...duty forklift that can carry the weight of the converter Make sure that the reach of the fork lift is long enough The package is wide and the center of gravity is far from the edges Do not tilt The c...

Page 44: ...Pulling and pushing Free width for fork tines 750 mm 30 in Moving the converter on rollers Do not move the converter on rollers 44 Mechanical installation...

Page 45: ...Obey these instructions when there are no ABB lift adapter bars in use 1 Attach the lifting slings to holes of the lifting bars a Use long enough slings See the minimum lifting angle in the figure bel...

Page 46: ...an be installed with its back against a wall Fasten the cabinet to the floor and wall roof Install the converter in an upright vertical position Notes Leave a 400 mm 16 in clearance above the converte...

Page 47: ...key delivered with the cabinet Open the handles 2 Detach the upper part of the door 3 Lift the door upwards 1 2 3 Miscellaneous Cable duct in the floor below the cabinet Prevent the cooling air flow f...

Page 48: ...ithin 0 5 meters 1 6 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...

Page 49: ...mmendations given by ABB are not followed the converter may experience problems that the warranty does not cover Selecting the grid disconnecting device The converter is equipped with a main circuit b...

Page 50: ...for the converter use ie it can withstand the voltage peaks at of the converter Use insulated N end non driven end bearing in the generator Make sure that the generator insulation meets the requiremen...

Page 51: ...consult the generator manufacturer regarding bearing and disturbance shielding In a non symmetrical four conductor system voltage can be induced to the separate PE conductor which rises generator fra...

Page 52: ...tity of parallel conductors per phase Conductor type Cable type Converter type ACS880 77CC 185 mm2 240 mm2 300 mm2 2 10 2 9 2 6 Copper EPR 6880A 5500A 7 Grid cables Total quantity of parallel conducto...

Page 53: ...61800 5 1 PE Symmetrical shielded cable with three phase conductors and symmetrically con structed PE conductor and a shield The PE conductor must meet the requirements of IEC 61800 5 1 PE Power cabl...

Page 54: ...cables in grid cabling Use symmetrical grid cabling Asymmetry leads to unequal current distribution between the conductors which may cause disturbances and fault trips To avoid asymmetry use symmetri...

Page 55: ...rounded directly in the wind turbine converter The other end of the shield should be left unconnected or grounded indirectly via a high frequency high voltage capacitor of a few nanofarads The screen...

Page 56: ...erference caused by the rapid changes in the converter output voltage Where control cables must cross power cables make sure they are arranged at an angle as near to 90 as possible Do not run extra ca...

Page 57: ...current of the converter No additional protection devices are needed Protecting the converter generator cable and grid cable against thermal overload The converter protects itself the grid cables and...

Page 58: ...es are installed in the generator cable between the converter and the generator Install the equipment in a metal enclosure in a way that the conduit or generator cable shielding runs consistently with...

Page 59: ...230 V AC 230 V AC 24 V DC 1 2 3 4 Relay outputs 1 Varistor 2 RC filter 3 Diode 4 Planning the electrical installation 59...

Page 60: ...60...

Page 61: ...t necessarily match the installation specific circuit diagrams of a tailor made wind turbine converter Checking the insulation of the assembly WARNING See and obey the safety instructions of the conve...

Page 62: ...ation resistance of an ABB generator must exceed 100 Mohm reference value at 25 C 77 F For the insulation resistance of other generators please consult the manufacturer s instructions Note Make sure t...

Page 63: ...main breaker 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 grid cable terminals 3 Lead the grid cabl...

Page 64: ...he cover on top of the converter modules is installed WARNING Foreign objects inside the converter module can cause eg short circuit Injury or death or damage to the equipment can occur 4 When shielde...

Page 65: ...ing Then remove the cover WARNING The cover on top of the converter modules can cause overheating Injury or death or damage to the equipment can occur 7 Refit the shroud removed earlier and close the...

Page 66: ...he auxiliary control cubicle Description Connector Customer connection for 400 V AC non UPS auxiliary power supply X1 Customer connection for 230 V AC UPS auxiliary power supply X2 Customer connection...

Page 67: ...p Go through the checklist together with another person WARNING Only qualified electricians are allowed to carry out the work described below Do the tasks described in the safety instructions of the c...

Page 68: ...the technical data The generator cable has been connected to the appropriate terminals the phase order is right and the terminals have been tightened Pull the conductors to check For tightening torque...

Page 69: ...e intervals and instructions Maintenance intervals The table below shows the maintenance tasks which can be done by the end user For more information consult your local ABB Service representative http...

Page 70: ...I I I I I I I I I I I I Checking ambient conditions dustiness corrosion temperat ure I I I I I I I I I I I I Checking the quality of auxiliary voltage I P I P I P I P I P I P I P I P I P I P I P I P...

Page 71: ...maintenance timers and counters that can be configured to generate a warning when a pre defined limit is reached Each timer counter can be set to monitor any parameter This feature is especially usefu...

Page 72: ...ilable from ABB Do not use other than ABB specified spare parts All the fans in the converter are of the same type Replacing the cooling fan of the converter module WARNING Only qualified electricians...

Page 73: ...2a 3b 4c 5 Air flow direction is towards the converter module Maintenance 73...

Page 74: ...t door Remove all the fasteners from the support plate on top of the grating and remove the support plate 3 Lift the grating and pull it away from the door 4 Remove the air filter 5 Remove all the fas...

Page 75: ...s and make sure it is safe to start the work See the safety instructions 2 The cooling fan of the auxiliary control cubicle is located in the lower part of the cubicle Open the door of the auxiliary c...

Page 76: ...work See the safety instructions 2 Open the door of the LCL filter cubicle The cooling fans of the LCL filter cubicle are located in the lower part of the cubicle 3 Disconnect the wiring plug of the...

Page 77: ...death or damage to the equipment can occur 1 Disconnect the converter from the all power sources and make sure it is safe to start the work See the safety instructions 2 Remove the shrouds in front o...

Page 78: ...ath or damage to the equipment can occur 1 Disconnect the converter from the all power sources and make sure it is safe to start the work See the safety instructions 2 Remove the shrouds in front of t...

Page 79: ...dule are sharp Use protective eyewear when working with the liquid cooling system Beware not to drop the screws inside the module Do not tilt the module Do not leave the module unattended on a sloping...

Page 80: ...4 5 5 5 6 6 6 7 Remove the pipe clamps from top tubes 7 7 8 Open top liquid connection nut with 30 mm wrench Pull the pipe upwards to release it 9 Open two module support bolts from top 8 9 9 80 Maint...

Page 81: ...e it 11 Remove the module bottom support by opening 3 pcs of M6 screws and 2 pcs of M8 screws 12 Open 2 pcs of Taptite M6 screws 12 10 11 11 11 11 11 12 13 Open Taptite M6 screw on the floor 13 14 Ope...

Page 82: ...14 15 Install 3 pcs of M6 Taptite screws removed earlier to secure the installation stand Tightening torque is 5 N m 3 7 lbf ft 82 Maintenance...

Page 83: ...ert M8 bolt to the hole on the top part of the module and turn it clockwise This will help in pushing the module out It also helps in pulling simultaneously from the handle while turning the screw 16...

Page 84: ...o a pallet or other platform for transportation 20 Install a new module in reverse order Tightening torque for cooling connectors is 10 N m 7 4 lbf ft in room temperature around 20 C 68 F Note You can...

Page 85: ...er from the all power sources and make sure it is safe to start the work See the safety instructions Replacing the memory unit The memory unit is located on the BCU control unit WARNING Do not remove...

Page 86: ...e 2 Insert the new card in reverse order Tightening torque for fastening screw is 0 7 N m 0 5 lbf ft Repeat the replacement procedure for other BCU control unit if needed Replacement illustration A 2...

Page 87: ...Generator side converter ratings Nominal voltage see also section Grid specification page 91 UN Typical generator power The power ratings apply at nominal voltage 690 V Pgen Continuous rms current of...

Page 88: ...emperature see section Temperature limits page 121 Altitude derating At altitudes above 1000 m 3281 ft above sea level the derating is 1 for every 100 m 328 ft on maximum continuous current This can b...

Page 89: ...539 Fuses for the voltage measurement board BAMU The fuse type is Mersen FR14GR69V2T 2 A Fuses of the DC chopper The fuse type is 170M4243 1000 V Dimensions weights and free space requirements See als...

Page 90: ...s to both sides of the connection busbar Grid side power connection enters the cabinet at the bottom of the cabinet Tightening torques Torque Screw size 4 N m 3 lbf ft M5 9 N m 6 6 lbf ft M6 22 N m 16...

Page 91: ...ith a power factor less than 1 Maximum allowable pro spective short circuit cur rent IEC 60439 1 UL 508 C 1 0 1 Power factor Total harmonic current distortion n 2 40 5 Total harmonic voltage distortio...

Page 92: ...the converter cabinet is not allowed in any operational circumstances 2 ABB additional extension to ambient surrounding temperature outside the cabinet 30 C 55 C 22 F 131 F See also the instructions f...

Page 93: ...humidity is 60 in the presence of corrosive gases No conductive dust allowed Contamination levels IEC 60721 3 3 IEC 60721 3 2 IEC 60721 3 1 Boards with coating Chemical gases Class 2C2 Solid particle...

Page 94: ...esources and energy Product parts and materials should be dismantled and separated Generally all metals such as steel aluminum copper and its alloys and precious metals can be recycled as material Pla...

Page 95: ...ectronic converter systems and equipment Part 1 General IEC 62477 1 2012 AMD1 2016 Adjustable Speed Electrical Power Drive Systems Part 5 1 Safety Requirements Electrical Thermal and Energy See sectio...

Page 96: ...operate without problems within an electromagnetic environment Likewise the equipment must not disturb or interfere with any other product or system within its locality First environment includes est...

Page 97: ...re manual for setting Default setting is off the setting must be activated at start up The converters are to be used in a heated indoor controlled environment See the ambient conditions for specific l...

Page 98: ...pplication of authentication measures encryption of data installation of anti virus programs etc to protect the product the network its system and the interface against any kind of security breaches u...

Page 99: ...its used in the ACS880 77CC converter see the circuit diagrams delivered with the converter General BCU control unit The BCU control unit consists of a BCON control board and a BIOC I O and power supp...

Page 100: ...ut AI2 I current U voltage AI2 Termination switch for drive to drive link D2D D2D TERM Ground selection Determines whether DICOM is separated from DIOGND ie the common reference for the digital inputs...

Page 101: ...transmitter VxR receiver V1T V1R V2T V2R Fiber optic connection to converter modules 3 7 BCU 12 22 only VxT transmitter VxR receiver V3T V3R V7T V7R Fiber optic connection to converter modules 8 12 B...

Page 102: ...itch 5 mm wire size 2 5 mm2 Digital inputs outputs DIO1 and DIO2 XDIO 1 and XDIO 2 As inputs 24 V logic levels 0 5 V 1 15 V Rin 2 0 kohm Fil tering 1 ms Input output mode selection by paramet ers As o...

Page 103: ...sical layer RS 485 Connector pitch 5 mm wire size 2 5 mm2 Safe torque off connection XSTO Input voltage range 3 30 V DC Logic levels 0 5 V 1 17 V Note For the converter to start both connections must...

Page 104: ...104...

Page 105: ...ts used in the ACS880 77CC converter see the circuit diagrams delivered with the converter General BCU control unit The BCU control unit consists of a BCON control board and a BIOC I O and power suppl...

Page 106: ...ut AI2 I current U voltage AI2 Termination switch for drive to drive link D2D D2D TERM Ground selection Determines whether DICOM is separated from DIOGND ie the common reference for the digital inputs...

Page 107: ...transmitter VxR receiver V1T V1R V2T V2R Fiber optic connection to converter modules 3 7 BCU 15 25 only VxT transmitter VxR receiver V3T V3R V7T V7R Fiber optic connection to converter modules 8 12 B...

Page 108: ...Description CAN bus connection XCAN XCAN 108 BCU x5 control unit...

Page 109: ...itch 5 mm wire size 2 5 mm2 Digital inputs outputs DIO1 and DIO2 XDIO 1 and XDIO 2 As inputs 24 V logic levels 0 5 V 1 15 V Rin 2 0 kohm Fil tering 1 ms Input output mode selection by paramet ers As o...

Page 110: ...ue off connection XSTO Input voltage range 3 30 V DC Logic levels 0 5 V 1 17 V Note For the converter to start both connections must be 1 EMC immunity according to IEC 61326 3 1 Connector pitch 5 mm w...

Page 111: ...imension drawings Contents of this chapter This chapter contains dimension drawings of the wind turbine converter See also the dimension drawings delivered with the converter 12 Dimension drawings 111...

Page 112: ...112 Dimension drawings...

Page 113: ...Dimension drawings 113...

Page 114: ...114 Dimension drawings...

Page 115: ...oling and heating circuit The following diagram shows how coolant circulates in the grid side converter LCL filter main breaker and generator side converter cubicles of the wind turbine converter The...

Page 116: ...B1 B2 6 1 2 3 4 5 Choke 1 1 Choke 2 2 Generator side converter modules 3 Grid side converter modules 4 Coolant OUT 5 Coolant IN 6 116 Cooling and heating...

Page 117: ...he cooling system are listed in section Specifications page 121 Coolant temperature control The temperature of the coolant in the internal cooling circuit must be kept within the limits specified in s...

Page 118: ...ta for the pipe materials 4 Position the liquid pipe ends against each other 5 Centre the connector onto the pipe ends 6 Tighten the threaded connector carefully and ensure that it is slid on the pipe...

Page 119: ...the converter is filled up coolant will start flowing from the bleed hose of the converter Let some coolant flow out before closing the bleed valve 5 Let any air remaining in the system out through th...

Page 120: ...r suitable container Extend the standard hoses when necessary 2 Open the bleed valve to let air displace the liquid 3 If required dry the piping with compressed oil free air of less than 6 bar 600 kPa...

Page 121: ...m coolant inlet temperatures Min Tcoolant C Tair C RH 40 RH 50 RH 65 RH 80 RH 95 7 4 4 5 0 9 1 9 4 3 5 3 0 0 1 3 7 6 7 9 2 10 1 5 4 6 8 4 11 5 14 2 15 6 0 9 4 13 2 16 5 19 2 20 10 5 13 8 17 9 21 4 24...

Page 122: ...ion Note The following requirements apply to the water to be used in the coolant not the water glycol inhibitor mixture 6 0 8 0 pH value 50 mg l Chloride 50 mg l Fluoride 100 mg l Sulphate 200 mg l no...

Page 123: ...ive WARNING Do not mix different approved coolants in any conditions Replace the cooling liquid always with same cooling liquid Mixing different coolant types is a risk for cooling system corrosion Ma...

Page 124: ...out page 124 Cold start with cold climate kit Converter can be equipped with optional cold climate kit in cold environments in which temperatures are lower than specified in the manual Cold climate v...

Page 125: ...rter ABB reserves right to change the dry out procedure based on examinations and tests Automatic software controlled dry out Some of the latest versions of the ACS880 wind turbine converter variants...

Page 126: ...126...

Page 127: ...estion A listing of ABB sales support and service contacts can be found by navigating to www abb com searchchannels Product training For information on ABB product training navigate to new abb com ser...

Page 128: ...www abb com windconverters 3AXD50000813605A Copyright 2021 ABB All rights reserved Specifications subject to change without notice 3AXD50000813605 Rev A EN EFFECTIVE 2021 12 22...

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