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BCU-x5 control unit

Contents of this chapter

This chapter describes the layout and connections of the BCU-x5 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 ACS880-87LC 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-x5”
represents the control unit types BCU-15/-25.

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Summary of Contents for ACS880-87LC-3200A

Page 1: ... ABB WIND TURBINE CONVERTERS ACS880 87LC 3200A 3200A 7 wind turbine converters Hardware manual ...

Page 2: ......

Page 3: ...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 ...

Page 4: ......

Page 5: ...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 hardware description 27 Contents of this chapter 27 Operation principle 28 Generator control 29 Overview diagram of the wind turbine converter 31 Layout drawings 33 Overview of power and control connections 34 Circuit boa...

Page 6: ...ents 55 Conduit 55 Armored cable shielded power cable 55 Selecting the control cables 55 General rules 56 Relay cable 57 Routing the cables 58 Control cable ducts 58 Protecting the converter installation 58 Protecting the grid cable in short circuit situations 58 Protecting the generator and generator cable in short circuit situations 58 Protecting the converter generator cable and grid cable agai...

Page 7: ...ng fan of the converter module 76 Replacing the fans of the main breaker cubicle 77 Replacing the cooling fan of the auxiliary control cubicle 78 Replacing the cooling fan of the LCL filter cubicle 79 Fuses 79 Replacing the DC fuses 80 Replacing the AC fuses 81 Replacing the DC chopper fuses 82 Converter module 82 Replacing the converter module 82 Required tools 88 Capacitors 88 BCU control unit 8...

Page 8: ...ions 98 Materials 98 Auxiliary circuit current consumption 99 Applicable standards 99 CE marking 99 Compliance with the European Low Voltage Directive 99 Compliance with the European EMC Directive 99 Compliance with the European Machinery Directive 100 Regulatory Compliance Mark RCM 100 EAC Eurasian Conformity marking 100 Compliance with EN 61800 3 2004 A1 2012 100 Definitions 100 Category C4 101 ...

Page 9: ...anical installation 122 Connecting the internal cooling circuit to a customer cooling unit 122 Connecting the liquid pipes 122 Filling up and bleeding the internal cooling circuit 123 Converters with a customer cooling unit 124 Draining the internal cooling circuit 125 Specifications 125 Temperature limits 126 Pressure limits 126 Water quality 126 Freeze protection and corrosion inhibition 126 Coo...

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Page 11: ...ause 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...

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: ...acuum 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 Als...

Page 14: ...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...

Page 15: ...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...

Page 16: ...uctions 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...

Page 17: ...o 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 warni...

Page 18: ...5 1 3 4 6 8 7 2 18 Safety instructions ...

Page 19: ... 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 swi...

Page 20: ...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 s...

Page 21: ... personnel safety in all circumstances and to reduce electromagnetic emission and interference Make sure that the conductivity of the grounding conductors is sufficient See the converter hardware manual Obey the local regulations In a multiple converter installation connect each converter separately to the protective earth PE Note You can use power cable shields as grounding conductors only when t...

Page 22: ... 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 If such substance is swallowed or gets into the eyes seek medical advice To avoid breaking the coolant pipes do not overtighten the nuts of the unions Blue connectors Leave 2 3 millimeters 0 08 0 12 i...

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 This manual deals with the wind turbine converters made of the modules of the frame size R9iLC The frame size of each converter type is indicated in the technical data The instructions technical data...

Page 24: ...tion 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 57 Route the cables Mechanical installation page 41 Move the converter to the installation site and attach it to the floor Cooling and heating page 119 Connect an external cooling circuit to the converter Ch...

Page 25: ...romagnetic compatibility EMC 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 module FEN 31 Optional Ethernet adapter module FENA Optional digital I O extension module FIO 01 Optional analog I O extension module FIO 11 Optional PROFIBUS DP adapter modu...

Page 26: ...ers firmware manual 3AXD50000022022 ACS880 77LC 87LC 87CC wind turbine converters system description 3AUA0000094606 Drive composer start up and maintenance PC tool user s manual Manuals and quick guides for I O extension modules fieldbus adapters etc Other documents Circuit diagrams set Fieldbus interface description Firmware release note with the download instructions For manuals contact your loc...

Page 27: ...et 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 back to back connected cubicles that contain the grid side converter modules generator side converter modules LCL filter terminals or grid busbars for grid cables and terminals for generator cables internal control ...

Page 28: ...intermediate 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 phase current is measured for ground fault protection 28 Operation principle and hardware description ...

Page 29: ...IBUS ADAPTER INPUT OUTPUT CONNECT IONS SAFETY CHAIN CURRENT TRANSFORMER 01 DISEL INPUT 690VAC Potential Transformer 3 G 3 WIND TURBINE GENERATOR MASTER 1 CABINET 01 T1 1 T1 2 T1 3 T1 4 F5 43 44 2 11 1 2 3 3 2 3 3 2 3 3 F1 21 23 3 F1 31 33 3 F1 41 43 3 01 5 Q10 3 3 F4 1 3 3 Q6 R6 1 7 F9 1 2 2 X4 X7 X1 Q1 3 I I 01 4 R5 21 23 R5 31 33 R5 41 43 F4 41 42 2 F5 33 34 2 F4 31 32 2 F5 23 24 2 F4 21 22 2 11...

Page 30: ... 2 2 3 K2 3 K1 3 3 A80 RJ45 4 K512 X1 01 T1 1 T1 2 T1 3 T1 4 AUX POWER OUTPUT 690VAC DISEL INPUT 690VAC F5 43 44 2 11 1 2 3 3 2 3 3 2 3 3 F1 21 23 3 F1 31 33 3 F1 41 43 3 01 5 Q10 3 3 F4 1 3 3 Q6 R6 1 7 F9 1 2 2 X4 X7 X1 Q1 3 I I 01 4 R5 21 23 R5 31 33 R5 41 43 F4 41 42 2 F5 33 34 2 F4 31 32 2 F5 23 24 2 F4 21 22 2 11 4 F5 13 14 2 F4 11 12 2 C8 C12 C1 C7 F7 1 3 3 F6 1 3 3 01 6 R20 Q2 3 3 X3 1 2 3 ...

Page 31: ...le 1 Main breaker cubicle 2 Additional cubicle for adjusting cooling connections 3 Generator connection terminals U V W in the plinth 4 Generator side converter modules 5 DC fuses 6 Main circuit breaker Q1 7 Grid connection terminals L1 L2 L3 8 Integrated DC resistors 9 Cooling connections 10 Operation principle and hardware description 31 ...

Page 32: ...e 2 LCL filter components 3 Cooling fans of the LCL filter cubicle 4 Grid side converter AC fuses 5 Grid side converter modules 6 Grid side converter DC fuses 7 Auxiliary control cubicle containing control units control electronics etc 8 32 Operation principle and hardware description ...

Page 33: ...nd communication BCON CH0 CH1 CH2 CH3 BCON L1 L2 L3 U2 V2 W2 PSL PSL FXXX XCAN S500 CI581 CN S500 AI523 1 3 4 6 7 1 2 5 CH0 CH1 CH2 CH3 2 Description No Slots 1 3 1 RDCO slot 4 2 BCU x5 control unit 3 BCU x2 control unit 4 External control via Ethernet and selected fieldbus optional and customer specified Both BCU control units are connected to Ethernet switch 5 Grid side converter 6 Generator sid...

Page 34: ...ctions between the circuit boards of the converter For further details see the delivery specific circuit diagrams For information on the BCU control unit see chapters BCU x2 control unit and BCU x5 control unit 34 Operation principle and hardware description ...

Page 35: ...ng 1 Charging ACB spring motor 1 Charging Convertor fault 1 No Fault ACU heater control 1 Heating ON LCL KLIXONS 1 OK ACB status 1 Closed ACB ready to close 1 Ready to close ACB tripped 0 Tripped ICU smoke detector 0 Fault Alarm ICU 1 fan alarm 1 OK ACU OPU 1 fan alarm 1 OK LCL air temperature ICU air temperature INU inside air temperature K1 winding temperature K2 winding temperature K2 cooling e...

Page 36: ...r charging 1 Charging ACB spring motor 1 Charging Convertor fault 1 No Fault ACU heater control 1 Heating ON LCL KLIXONS 1 OK ACB status 1 Closed ACB ready to close 1 Ready to close ACB tripped 0 Tripped ICU smoke detector 0 Fault Alarm ICU 1 fan alarm 1 OK ACU OPU 1 fan alarm 1 OK LCL air temperature ICU air temperature INU inside air temperature K1 winding temperature K2 winding temperature K2 c...

Page 37: ... includes ratings valid markings type code and serial number of the converter Each converter module is also individually labeled Typical label is shown below 1 2 3 5 6 7 4 Serial number The first digit of the serial number refers to the manufacturing plant The next four digits refer to the converter s manufacturing year and week respectively The remaining digits complete the serial number so that ...

Page 38: ... and configuration The first 23 digits form the basic code It describes the basic construction of the wind turbine converter The fields in the basic code are separated with hyphens The option codes follow the basic code Each option code starts with an identifying letter common for the whole product series followed by descriptive digits The option codes are separated by plus signs The selections ar...

Page 39: ...nents C129 Cooling connections on the right side C143 Flange for cooling liquid connections of size DN64 with flange clamp ISO 6162 1 2002 C171 Grid control options Grid fault ride through F276 Cabinet options Current transformers for grid current measurement G335 Auxiliary 3 phase power output 125 A G396 Fieldbus Interbus S adapter module K453 FPBA 01 PROFIBUS DP adapter module K454 Modbus Plus a...

Page 40: ... DDCS communication 2 L509 Control PMSM control system application N677 PMSM STD N679 PMSM External Control N680 Safety Emergency Stop Category 0 Q951 Documentation language delivered set may include documents in English English R700 Specialities Customized described in Technical Appendix P902 Extended warranty 1 P904 Extended warranty 2 P909 Service plan 1 P910 Service plan 2 P911 Seaworthy packi...

Page 41: ...l 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 installation 41 10 ...

Page 42: ...ions crane or fork lift check the load capacity iron 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 delivered by ABB are included in the delivery They are inside the cabinet The delivery does not contain screws or tools to install the cabinet to the floor to...

Page 43: ...f 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 center of gravity is high Move only in the upright position Moving Pulling Pushing Moving the converter on rollers Do not move the converter on rollers Mechanical installation 43 10 ...

Page 44: ...hese instructions when ABB lifting bars are 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 below WARNING Divide the weight to all lifting bars and all holes If you do not divide the load evenly the lifting bars can not carry the weight of the converter 2 Tighten the slings steadily and make sure that the load is ...

Page 45: ...n You cannot install it with the longer side against a wall Install the converter in an upright vertical position Notes Leave a 400 mm 16 in clearance above the converter cabinet to allow pressure release lids to open in an arc fault situation Leave space at the side for the coolant pipes You can adjust the height for example if the floor is uneven by using metal shims between the cabinet frame an...

Page 46: ... do not recommend welding see section Electric welding page 47 Internal cooling circuit For installations related to cooling see chapter Cooling and heating Lifting the door 1 Unlock the door with the triangle key delivered with the cabinet Open the handles 2 Detach the upper part of the door 3 Lift the door upwards 1 2 3 46 Mechanical installation ...

Page 47: ...protection fire protection and EMC compliance Electric welding It is not recommended to fasten the cabinet by welding If you must do it for some reason Weld only the flat bar under the cabinet never the cabinet frame itself Clamp the welding electrode onto the flat bar about to be welded or to the next flat bar of the cabinet within 0 5 meters 1 6 of the welding point WARNING If the welding return...

Page 48: ...48 ...

Page 49: ...rter may experience problems that the warranty does not cover Selecting the grid disconnecting device The converter is equipped with a main circuit breaker as standard The breaker is withdrawable when withdrawn cranked out the breaker operates as a main disconnector for the converter However the withdrawn main breaker does not isolate the grid cable terminals of the converter from the grid Equip t...

Page 50: ...erter 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 requirements in the table below Select the cables according to the instruction in this manual Install the converter and its cabling as instructed in this manual Protecting the generator insulation and bearings The generato...

Page 51: ...e shielding In a non symmetrical four conductor system voltage can be induced to the separate PE conductor which rises generator frame potential and causes current to ground through the generator bearings and shaft This causes extra wear Whereas in a symmetrical shielded cable the high capacitance between the PE conductor and the phase conductors forms an LC filter reducing bearing currents and vo...

Page 52: ...s per phase Conductor type Cable type Converter type ACS880 87LC 95 mm2 120 mm2 185 mm2 240 mm2 2 12 2 12 2 9 2 8 Copper EPR 3200A 3200A 7 Grid cables Total quantity of parallel conductors per phase Conductor type Cable type Converter type ACS880 87LC 95 mm2 120 mm2 185 mm2 240 mm2 2 12 2 11 2 8 2 7 Copper EPR 3200A 3200A 7 DC resistor cables Number of conductor pairs per DC chopper module Conduct...

Page 53: ...C 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 cable types for limited use A four conductor system three phase conductors and a protective conductor on a cable tray is not recommended for cabling PE Not allowed power cable types A four conductor syst...

Page 54: ...e 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 symmetrical multicore three phase cables where possible Single core cabling is also allowed if the cables are grouped symmetrically The table below shows three possible cabling options Description Layout No ...

Page 55: ... grounded 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 can also be grounded directly at both ends if they are in the same earth line with no significant voltage drop between the end points Use a double shielded twisted pair cable see figure a for analog...

Page 56: ... Relay cable The cable type with braided metallic screen for example ÖLFLEX from Lapp Kabel Germany has been tested and approved by ABB 56 Planning the electrical installation ...

Page 57: ...age 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 cables through the converter The cable trays must have good electrical bonding to each other and to the grounding electrodes You can use aluminum tray systems to improve local equalizing of potential A diagram of the cable routing is below 90 min 500 mm 20 in min 200 ...

Page 58: ...l 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 generator cables against thermal overload when the cables are sized according to the nominal current of the converter and ambient conditions are within the limits specified under ambient conditions ...

Page 59: ...xiliary circuit page 65 Using a safety switch between the converter and generator To minimize the emission level when safety switches 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 without breaks from the converter to the generator Protecting the contact...

Page 60: ...230 V AC 230 V AC 24 V DC 1 2 3 4 Relay outputs 1 Varistor 2 RC filter 3 Diode 4 60 Planning the electrical installation ...

Page 61: ...ot 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 converter If you ignore them injury or death or damage to the equipment can occur Converter Every converter has been tested for insulation between the main circuit and the chassis at the factory Also ther...

Page 62: ...lation 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 that there is no condensed moisture inside the generator casing If you suspect that there is moisture dry the generator before measurement Note When using permanent magnet generator it must be stable ...

Page 63: ...ctions Aluminum aluminum contact can cause oxidation in the contact surfaces 1 Grid connection terminals are located in the plinth of the converter Fasten the grid cables to the grid connection terminals Connect the phase conductors to terminals L1 L2 and L3 Tighten the conductors to 120 N m 89 lbf ft 2 Connect ground conductors or cables to the cabinet PEN ground busbar 3 Provide support for the ...

Page 64: ...Obey the grease manufacturer s instructions Aluminum aluminum contact can cause oxidation in the contact surfaces 1 Generator connection terminals are located in the plinth of the converter Fasten the generator cables to the generator connection terminals Connect the phase conductors to terminals U V and W Tighten the conductors to 120 N m 89 lbf ft 2 Connect ground conductors or cables to the cab...

Page 65: ...cuit can be supplied from the customer diesel generator Connect the external diesel generator supply to the terminals X4 5 6 7 8 that are located in the plinth Then switch OFF the auxiliary voltage circuit breaker Q2 and switch ON the breaker Q3 See the circuit diagrams delivered with the converter Electrical installation 65 11 ...

Page 66: ...auxiliary power output Diesel generator input X4 Service outlet X115 Supply for light X114 Supply for service options 1 X202 Supply for service options 2 X117 690 V supply for A3 nacelle main control panel X201 Main supply and control voltage nacelle A3 cabinet X107 Fiber optic from A3 A100 A101 K611 Converter cooling fan supply 1 X101 Converter cooling fan supply 2 X106 Supply tower fan placed ya...

Page 67: ...Converter coolant heating X104 Converter coolant level X119 Default I O connection diagrams See the circuit diagrams delivered with the converter Electrical installation 67 11 ...

Page 68: ...68 ...

Page 69: ...up 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 converter If you ignore them injury or death or damage to the equipment can occur 1 Open the main disconnector of the converter and lock it to open position 2 Ensure by measuring that the converter is...

Page 70: ... For tightening torques see 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 torques see the technical data The generator cable and DC resistor cable if present has been routed away from other cables Converters which have a DC chopper option D150 with a c...

Page 71: ...preventive maintenance 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 www abb com searchchannels 8 Maintenance 71 ...

Page 72: ...ing the quality of auxiliary voltage Improvements I I I I I I I I I I I I I Firmware and hardware upgrade based on product notes Measurements and tests P P P P P P P P P P P P Functional test with net voltage P P P P P P P P P P P P Basic measurements with supply voltage Spare parts P I P I P I P I P I P I Spare parts 3AXD10000552946 Symbols Inspection visual inspection and maintenance action if n...

Page 73: ...service reminder For more information see the firmware manual Power connections Tightening WARNING Only qualified electricians are allowed to do this work Read the complete safety instructions of the converter If you ignore the instructions physical injury death or damage to the equipment can occur 1 Disconnect the converter from the all power sources including UPS and make sure it is safe to star...

Page 74: ...odule a is located on top of the module Open the door of the converter module cubicle and remove the shroud in front of the fan 3 Disconnect the wiring plug of the fan b 4 Remove the fastening screws c of the fan support 5 Lift the fan unit out of the cabinet 6 Detach the fan from the support plate by loosening the fastening screws of the fan The fan grille is detached then too 7 Install a new fan...

Page 75: ...b 3 a 2 6 c 4 Air flow direction is towards the converter module Maintenance 75 ...

Page 76: ...it is safe to start the work See the safety instructions 2 The cooling fan of the main breaker cubicle is located in the lower part of the additional cubicle for adjusting cooling connections Open the door of the cubicle 3 Disconnect the wiring plug of the fan 4 Undo the four fastening screws of the fan The fan grille is detached then too 5 Pull the fan out 6 Install a new fan in reverse order Che...

Page 77: ...s 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 control cubicle 3 Disconnect the wiring plug of the fan 4 Undo the four fastening screws of the fan The fan grille is detached then too 5 Pull the fan out 6 Install a new fan in reverse order Check that the air flow direc...

Page 78: ...fe to start the 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 fan 4 Undo the fastening screws of the fan The fan grille is detached then too 5 Pull the fan out 6 Install a new fan in reverse order Check that the air flow direction is correct an ar...

Page 79: ...ury 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 of the fuses 3 Open the M10 screws and remove the fuses 4 Insert new fuses 5 Re assemble the parts in reverse order For the correct tightening torque see the technical data 2 3 Maintenance 79 ...

Page 80: ... 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 of the fuses 3 Open the M10 screws and remove the fuses 4 Insert new fuses 5 Re assemble the parts in reverse order For the correct tightening torque see the technical data 2 3 80 Maintenance ...

Page 81: ...t 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 DC chopper fuses are located in the top part of the grid side converter cubicle Remove the shrouds in front of the fuses 3 Open the nuts and remove the fuses 4 Insert new fuses 5 Re assemble the parts in reverse order For the correct tightening torque see the t...

Page 82: ... from the edge of the module front plate to avoid pinching them between the module and the cubicle Use protective gloves The edges of the module 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 floor 1 Disconnect the converter from the all power sources...

Page 83: ...s and X50 connectors Carefully place the cables on top of the fan 4 4 4 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 Maintenance 83 ...

Page 84: ...connection with 30 mm wrench Pull the pipe downwards to release 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 84 Maintenance ...

Page 85: ...14 Open the installation stand optional and place it in front of the module 14 Maintenance 85 ...

Page 86: ...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 15 15 15 86 Maintenance ...

Page 87: ...m 2 in and install the lifting hook to the lifting hole 17 18 Pull the whole module onto the installation stand Keep the pipes and wires away from the sharp edges and be careful not to damage the coolant connections 19 Lift the module onto 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 tem...

Page 88: ...ter 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 or insert the memory unit when the control unit is powered See b in figure Replacement illustration page 89 1 To remove the memory unit undo the fastening screw and pull the memory unit out 2 Insert ...

Page 89: ...re 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 1 A a a b c Main circuit breaker For ABB SACE main circuit breaker maintenance refer to the manufacturer s instructions 1SDH001000R0002 Maintenance 89 ...

Page 90: ... be replaced without removing the UPS unit from the cabinet For maintenance procedures see the manufacturer s instructions Auxiliary control cubicle 3 4 1 2 Description No UPS unit 1 Switch for battery supply 2 Battery 1 3 Battery 2 4 90 Maintenance ...

Page 91: ...ons Generator side converter ratings Nominal voltage see also section Grid specification page 95 UN Typical generator power The power ratings apply at nominal voltage 690 V Pgen Continuous rms current of the generator side converter I2 Apparent power Sn gen Grid side converter ratings Rated grid side converter power The power ratings apply at nominal voltage 690 V Pgrid Continuous rms current of t...

Page 92: ...s 0 5 for every 100 m 328 ft Derating is allowed only on maximum continuous current for grid and generator If the installation site is located higher than 2000 m 6562 ft above sea level contact your local ABB representative Alternatively the derating can be handled with cooling liquid temperature derating 1 C for every 100 m This means that in eg 2000 m installation the maximum liquid temperature ...

Page 93: ... 2 10362 2980 117 1417 56 2436 5 96 3200A 3200A 7 3AXD10000011539 For free space requirements see the dimension drawings delivered with the converter Losses cooling data and noise Noise Cooling data Losses Converter type ACS880 87LC Pressure loss Mass flow tolerance 2 20 Coolant quantity Air Liquid dBA kPa l min l kW kW UN 690 V 70 120 2 300 2 52 43 8 172 7 3200A 3200A 7 3AXD10000011539 Internal c...

Page 94: ... of the grid cable terminals see the dimension drawings Terminal and lead through data for the generator cables You can connect cable lugs to both sides of the cable connection busbar The lead throughs are acquired separately by the customer Generator cables enter the cabinet in the plinth Generator cable connection busbars are presented below See also the dimension drawings 94 Technical data ...

Page 95: ...otal harmonic current distortion n 2 40 5 Total harmonic voltage distortion n 2 40 5 when Rsc 7 Harmonic distortion Requirements for the grid connection For applicable grid codes contact your local ABB representative Generator connection data AC induction generators permanent magnet generators Generator types 0 110 U1 3 phase symmetrical Umax 750 V Voltage U2 8 200 Hz Output frequency f2 1 85 kHz ...

Page 96: ... ABB additional extension to ambient surrounding temperature outside the cabinet 30 C 55 C 22 F 131 F See also the instructions for ambient temperature derating 3 L denotes service life 15 years Disclaimer The customer shall ensure that the environmental conditions inside the wind turbine is maintained in order to fulfill the environmental classifications and or corrosion class as herein stated If...

Page 97: ...e 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 particles Class 2S2 Boards with coating Chemical gases Class 1C2 Solid particles Class 1S3 Boards with coating Chemical gases Class 3C2 Solid particles Class 3S2 60 106 kPa 0 6 1 05 atmospheres 70 106 kPa 0 ...

Page 98: ...erials should be dismantled and separated Generally all metals such as steel aluminum copper and its alloys and precious metals can be recycled as material Plastics rubber cardboard and other packaging material can be used in energy recovery Printed circuit boards and large electro lytic capacitors need selective treatment according to IEC 62635 guidelines To aid recycling plastic parts are marked...

Page 99: ...stallations BS7671 Enclosures for Electrical Equipment 1000 Volts Maximum NEMA 250 2003 Adjustable Speed Electrical Power Drive Systems Part 5 1 Safety Requirements Electrical Thermal and Energy See section ETL marking page 101 UL 61800 5 1 Guideline for Certification of Wind Turbines GL IV 1 2010 CE marking A CE mark is attached to the converter to verify that the converter follows the provisions...

Page 100: ...e 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 establishments connected to a low voltage network which supplies buildings used for domestic purposes Second environment includes establishments connected to a network not supplying domestic premises Drive of c...

Page 101: ... in the hardware manual 4 The converter is installed according to the instructions given in the hardware manual WARNING A drive of 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 ETL marking ETL according to UL marking on request The converters are ETL certifi...

Page 102: ... via network to commissioning tool is not necessary However it is Customer s sole responsibility to provide and continuously ensure a secure connection between the product and Customer network or any other network as the case may be Customer shall establish and maintain any appropriate measures such as but not limited to the installation of firewalls prevention of physical access application of au...

Page 103: ...its used in the ACS880 87LC 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 un...

Page 104: ...put 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 floats DICOM DIOGND 7 segment display Multicharacter indications are displayed as repeated se quences of characters U is indicated briefly before o Control program running Control program startup in...

Page 105: ...T 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 BCU 22 only VxT transmitter VxR receiver V8T V8R V12T V12R Data logger memory card for converter mod ule communication SD CARD Real time clock battery voltage is higher than 2 8 V If the LED is off wh...

Page 106: ...pitch 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 outputs Total output current from 24VD is limited to 200 mA DIO1 can be configured as a frequency input 0 16 kHz with hardware filtering of 4 microseconds for 24 V level square wave signal sinusoidal ...

Page 107: ...ysical 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 be 1 EMC immunity according to IEC 61326 3 1 Connector pitch 5 mm wire size 2 5 mm2 Safe torque off output XSTO OUT Connector RJ 45 Control panel connection X13 Cable length 3 m Connector RJ 45 Ether...

Page 108: ...108 ...

Page 109: ...its used in the ACS880 87LC 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 x5 represents the control un...

Page 110: ...put 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 floats DICOM DIOGND 7 segment display Multicharacter indications are displayed as repeated se quences of characters U is indicated briefly before o Control program running Control program startup in...

Page 111: ...T 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 BCU 25 only VxT transmitter VxR receiver V8T V8R V12T V12R Data logger memory card for converter mod ule communication SD CARD Real time clock battery voltage is higher than 2 8 V If the LED is off wh...

Page 112: ...Description CAN bus connection XCAN XCAN 112 BCU x5 control unit ...

Page 113: ...pitch 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 outputs Total output current from 24VD is limited to 200 mA DIO1 can be configured as a frequency input 0 16 kHz with hardware filtering of 4 microseconds for 24 V level square wave signal sinusoidal ...

Page 114: ...que 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 wire size 2 5 mm2 Safe torque off output XSTO OUT Connector RJ 45 Control panel connection X13 Cable length 3 m Connector RJ 45 Ethernet connection XETH Memory card type SDHC SDHC memory card slot SD ...

Page 115: ...Dimension 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 115 ...

Page 116: ...116 Dimension drawings ...

Page 117: ...Dimension drawings 117 ...

Page 118: ...118 Dimension drawings ...

Page 119: ...omponents and transfers the heat to the external cooling circuit that is usually part of a larger external cooling system Diagram of the internal cooling and heating circuit The following example diagram shows how coolant circulates in the auxiliary control grid side converter LCL filter main breaker and generator side converter cubicles of the wind turbine converter 13 Cooling and heating 119 ...

Page 120: ...6 7 2 3 4 5 1 1 Choke 1 Bleeding valve 2 Draining valve 3 Grid side converter modules 4 Generator side converter modules 5 Coolant OUT 6 Coolant IN 7 120 Cooling and heating ...

Page 121: ...The materials used in the cooling system are listed in section Specifications page 125 Coolant temperature control The temperature of the coolant in the internal cooling circuit must be kept within the limits specified in section Specifications page 125 Note that the minimum temperature depends on ambient temperature and relative humidity The following diagram shows an example of coolant temperatu...

Page 122: ...ata 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 ends The use of appropriate sealant is recommended flange bolts to a minimum torque of 70 N m 52 lbf ft 7 Make sure that the liquid pipes are securely connected Filling up and bleeding the internal ...

Page 123: ...it with coolant For coolant specification see below 4 After the converter is filled up coolant will start flowing from the bleeding hose of the converter Let some coolant flow out before closing the bleeding valve 5 Let any air remaining in the system out through the bleeding valve at the cooling unit 6 Close the bleeding valve at the cooling unit 7 Continue to fill in coolant until a base pressur...

Page 124: ...nd draining coolant 1 Lead the bleeding hose into a bucket or other suitable container Extend the standard hoses when necessary 2 Open the bleeding 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 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...

Page 125: ...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 1 25 15 0 18 4 22 7 26 2 29 1 30 19 4 23 0 27 4 31 1 34 1 35 23 8 27 6 32 2 35 9 39 0 40 28 2 32 1 36 8 40 8 44 0 45 32 8 36 7 41 6 45 6 49 0 50 37 1 42 2 46 3 50 4 53 9 55 Not allowed as standard but the coolant temperature must be 5 C 41 F or above Consult an ABB representative if ope...

Page 126: ...Chloride 50 mg l Fluoride 100 mg l Sulphate 200 mg l no deposits are allowed at the temperature of 57 C 153 F Total dissolved solids 250 mg l Total hardness as CaCO3 400 µS cm this equals the resistance of 2500 ohm cm Conductivity The use of purified water which is not intended for hu man consumption is forbidden The water must be clean of solid matter Freeze protection and corrosion inhibition WA...

Page 127: ...ling liquid Mixing different coolant types is a risk for cooling system corrosion Materials Materials used in the internal cooling circuit are stainless steel 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 gasket NBR nitrile rubber Use only these materials in the external cooling circuit too WARNING ...

Page 128: ...o ACU fan Aux supply reset BDPS control Manual recover power supply to control A1 A2 K7 1L1 2T1 026a 1D 3L2 4T2 026a 5D 5L3 6T3 027a 1D 7L4 8T4 027a 5D 12 11 14 K17 050a 2B A1 A2 K15 1L1 2T1 029a 1D 3L2 4T2 5L3 6T3 14 13 12 11 14 K22 050b 3C 32 31 34 K12 030d 2E A1 A2 K19 1L1 2T1 020b 3D 3L2 4T2 020b 4D 5L3 6T3 020b 5D 7L4 8T4 020b 5D 14 13 6D 12 11 14 K23 050b 4C 13 14 K19 5E 01 3 A1 A2 K8 1L1 2T...

Page 129: ...ature of liquid need to be adjusted to maximum possible level 45 C 50 C 113 F 122 F Normal start and start after the blackout When the thermostat T11 temperature in the auxiliary control unit is below 5 C 41 F There is no power supply for the control components in the auxiliary control unit The auxiliary control unit is heated with heater E1 Liquid heater and pump need to turn ON Modules are being...

Page 130: ...130 ...

Page 131: ...uestion 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 service training Providing feedback on ABB manuals Your comments on our manuals are welcome Navigate to new abb com drives manuals feedback form a1 frozen PDF A4 Created 2021 07 13 09 50 52 ...

Page 132: ...www abb com windconverters 3AXD50000721986A Copyright 2021 ABB All rights reserved Specifications subject to change without notice 3AXD50000721986 Rev A EN EFFECTIVE 2021 07 13 ...

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