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Maintenance 81

Symbols
I Inspection

(visual inspection and maintenance action if needed)

P Performance

of on/off-site work (commissioning, tests, measurements or other work)

R Replacement

Maintenance and component replacement intervals are based on the assumption that the equipment is
operated within the specified ratings and ambient conditions. ABB recommends annual inspections to ensure
the highest reliability and optimum performance.
Long term operation near the specified maximum ratings or ambient conditions may require shorter
maintenance intervals for certain components. Contact your local ABB Service representative for additional
maintenance recommendations.

Note 1:

Cooling liquid to be used is BASF Glysantin® G30® or Valvoline Zerex G30 mixed with tapwater. For

more details, see chapter

Cooling and heating

. In case practical examples or specific tests carried with the

above mentioned cooling mixture together with the cooling system materials the maintenance interval can be
revised.

Note 2:

The maintenance schedule of the main circuit breaker is according to maximum 1,000 operations of

the breaker per each year. Replacement after 6000 operations. For more information, refer to the maintenance
manual of the ABB SACE breaker.

Maintenance timers and counters

The control program has maintenance timers or 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 useful as a service reminder. For more
information, see the firmware manual.

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Summary of Contents for ACS880-87LC-4000A/4021A-7

Page 1: ... ABB WIND TURBINE CONVERTERS ACS880 87LC 4000A 4021A 7 and ACS880 87LC 4000A 4132A 7 wind turbine converters Hardware manual ...

Page 2: ...nual 3AUA0000120723 ACS880 77LC 87LC wind turbine converters start up guide 3AXD50000033775 ACS880 77LC 87LC wind turbine converters firmware manual 3AUA0000130879 Emergency stop stop category 0 option Q951 for ACS880 77LC 87LC wind turbine converters user s manual 3AXD50000040787 Drive composer Start up and maintenance PC tool user s manual 3AUA0000094606 Manuals for I O extension modules fieldbu...

Page 3: ...0A 4021A 7 and ACS880 87LC 4000A 4132A 7 wind turbine converters 3AUA0000120723 Rev D EN EFFECTIVE 2018 11 29 2018 ABB Oy All Rights Reserved 1 Safety instructions 4 Mechanical installation 6 Electrical installation Table of contents ...

Page 4: ......

Page 5: ...tion to the manual Contents of this chapter 23 Target audience 23 Purpose of the manual 23 Contents of the manual 24 Related documents 24 Categorization by frame size and option code 24 Quick installation commissioning and operation flowchart 25 Terms and abbreviations 26 3 Operation principle and hardware description Contents of this chapter 29 Operation principle 29 Generator control 30 Overview...

Page 6: ...types 58 Generator cable shield 58 Single core vs multicore cables in grid cabling 59 Additional US and Canada requirements 59 Conduit 59 Armored cable shielded power cable 59 Selecting the DC resistors 60 Selecting the control cables 60 General rules 60 Relay cable 60 Routing the cables 61 Control cable ducts 61 Protecting the converter installation 62 Protecting the grid cable in short circuit s...

Page 7: ...Checklist 78 8 Maintenance Contents of this chapter 79 Maintenance intervals 80 Maintenance timers and counters 81 Cabinet 82 Replacing inlet door filter IP54 customer variant 82 Power connections 83 Tightening 83 Fans 83 Replacing the cooling fan of the converter module 84 Replacing the fan of the main breaker cubicle 86 Replacing the cooling fan of the auxiliary control cubicle 89 Replacing the ...

Page 8: ...ntrol unit 112 Efficiency 112 Degree of protection 112 Environmental and corrosion classification 112 Ambient conditions 113 Materials 114 Auxiliary circuit current consumption 114 ACS880 87LC 4000A 4021A 7 and ACS880 87LC 4000A 4132A 7 114 UPS supply 114 Non UPS supply 114 Applicable standards 115 CE marking 115 Compliance with the European Low Voltage Directive 115 Compliance with the European E...

Page 9: ...l cooling circuit to a customer cooling unit 132 Connecting the liquid pipes 132 Filling up and bleeding the internal cooling circuit 133 Converters with a customer cooling unit 133 Draining the internal cooling circuit 134 Cooling station control 134 Specifications 136 Temperature limits 136 Pressure limits 136 Water quality 137 Freeze protection and corrosion inhibition 137 Coolant concentration...

Page 10: ...10 ...

Page 11: ...tell you about conditions which can cause injury or death or damage to the equipment They also tell you how to prevent the danger Notes draw attention to a particular condition or fact or give information on a subject The manual uses these warning symbols Electricity warning tells about hazards from electricity which can cause injury or death or damage to the equipment General warning tells about ...

Page 12: ...nverter against dust and burr Electrically conductive debris inside the drive can cause damage or malfunction Vacuum clean the area below the converter before the start up to prevent the converter cooling fans from drawing the dust inside the converter Do not cover the air inlet and outlet when the converter is running Make sure that there is sufficient cooling Before power switch on make sure tha...

Page 13: ...sconnect any external dangerous voltages from the control circuits such as relay outputs Open disconnect and lock out the breaker of the grid transformer as the main circuit breaker of the converter does not remove the voltage from the grid cable busbars and some auxiliary circuits Attach a warning notice to the disconnector Lock the turbine rotor and generator shaft Open the safety switch between...

Page 14: ...he converter unit may be at the main circuit potential Dangerous voltages can be present between the control boards and the frame of the converter unit when the main circuit voltage is on It is critical that the measuring instruments such as an oscilloscope are used with caution and safety always as a priority The fault tracing instructions give special mention of cases in which measurements may b...

Page 15: ... 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 16: ...ace 3 To access the crank turn the lower key and 4 press down the button next to the lower key 5 Pull out the crank 6 Insert the crank into the hole next to the lower key and turn the crank until it stops 7 Make sure that the rotating switch to the right of the crank is in the DISCONNECTED position 8 Lock the Push OFF switch to the Push OFF position with the key on the right Put the key s in a saf...

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

Page 18: ...18 Safety instructions 8 9 ...

Page 19: ...ng and disconnecting the main circuit breaker on page 16 2 In the charging cubicle turn the charging circuit switch Q10 from ON position a to the OFF position b 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 cir...

Page 20: ...g the main circuit breaker on page 16 2 In the charging cubicle turn the Q2 and Q3 disconnectors to the OFF position 3 Lock the Q2 and Q3 disconnectors to the OFF position with the locking plate and hang a padlock to the plate Disconnecting the internal 230 V and 400 V auxiliary power supply terminal X1 4 In the auxiliary control cubicle disconnect the cables on the terminal X1 3 2 Example photos ...

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

Page 22: ...s 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 of thread vis...

Page 23: ...pters sections in this manual and other manuals Target audience This manual is intended for people who plan the installation install commission use and service the converter Read the manual before working on the converter The reader is expected to know the fundamentals of electricity wiring electrical components and electrical schematic symbols The manual is written for readers worldwide Purpose o...

Page 24: ...ont cover 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 section Type equivalence table on page 108 The instructions technical data and dimensional drawings which concern only certain optional selections are marked with codes The options included in the...

Page 25: ... Check that all necessary option modules and equipment are present and correct Only intact converters may be started up Check the installation site Checklist before mechanical installation page 44 Route the cables Routing the cables page 61 Move the converter to the installation site and attach it to the floor Mechanical installation page 43 Connect an external cooling circuit to the converter Coo...

Page 26: ...l program runs See BCON Control unit Control board built in a rail mountable housing See BCU Converter Converts direct current and voltage to alternating current and voltage or vice versa Converter module Grid side converter or generator side converter module Cubicle One section of a cabinet installed wind turbine converter A cubicle is typically behind a door of its own DC link DC circuit between...

Page 27: ...the grid side converter Attenuates harmonics Main circuit breaker Electrically controlled main switching and protecting device A withdrawable breaker can also be used as the main disconnector MBC Main breaker cubicle containing main switching and disconnecting devices power terminals etc NETA 21 Remote monitoring tool Parameter User adjustable operation instruction to the converter or signal measu...

Page 28: ...28 Introduction to the manual ...

Page 29: ... turbines with an induction generator or a permanent 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 back to back connected cubicles that contain the grid side converter modules generator side converter modules LCL filter terminals or grid busbars for grid ca...

Page 30: ...h the generator side converter to the converter 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 ...

Page 31: ...Operation principle and hardware description 31 Overview diagram of the wind turbine converter An example single line diagram of the wind turbine converter is shown below ...

Page 32: ...32 Operation principle and hardware description Layout drawing Layout of the wind turbine converter is shown below 1 1 2 3 4 5 5 6 7 8 9 10 6 6 6 6 11 12 13 Front view 14 15 15 16 17 18 ...

Page 33: ...inals U2 V2 W2 8 Main circuit breaker Q1 9 Grid cable busbar terminals L1 L2 L3 10 Cooling fans of the main breaker cubicle M16 M17 M18 11 Capacitors of the LCL filter C1 C2 12 Terminals for the auxiliary power 01 6 13 Smoke detector customer variant A2 14 Coolant in option C144 cooling connectors left 15 Auxiliary power disconnectors Q2 X11 Q3 X12 16 Charging circuit switch Q10 17 Grounding point...

Page 34: ...34 Operation principle and hardware description 7 8 10 11 11 11 11 11 11 10 6 9 12 12 12 12 12 12 2 3 3 4 5 1 13 Back view 14 15 ...

Page 35: ...ing fans of the LCL filter cubicle M33 M34 9 Smoke detector customer variant A3 10 Grid side converter modules T1 Note ACS880 87LC 4000A 4021A 7 contains five grid side converter modules 11 Grid side converter DC fuses F5 12 Grid side converter AC fuses F1 13 Lower cooling fans of the LCL filter cubicle M20 M21 M22 14 BCU control units own for both grid side converter modules and generator side co...

Page 36: ...boards page 37 The option module slots on the control unit are reserved for internal use and communication External control via Ethernet Both BCU control units are connected to Ethernet switch Grid side converter Generator side converter BCON BCU control unit CH0 CH1 CH2 CH3 Slots 1 3 BCON BCU control unit RDCO slot 4 CH0 CH1 CH2 CH3 RDCO slot 4 L1 L2 L3 U2 V2 W2 Slots 1 3 PSL PSL FIO FXXX FXX RDC...

Page 37: ...s the interconnections between the control boards of the converter 1 1 Generator side converter module 2 Grid side converter module 1 1 1 1 2 2 2 2 2 2 Note ACS880 87LC 4000A 4021A 7 contains five grid side converter modules The modules are connected to CH1 CH5 and BAMU is connected to CH6 ...

Page 38: ...ts of the converter BAMU board The BAMU board is a multipurpose measurement unit for voltage and current measurement It has two three phase voltage inputs and three current inputs When the option F276 grid fault ride through is selected the BAMU board is included in the delivery for measuring three grid voltages ...

Page 39: ...l 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 there are no two converters with the same number 2 Type code See section Type designation key If the delivery contains a DC chopper option code D150 is marked in the converter label 1 1 2 3 4 5 2 4 ABB Oy Hiomotie ...

Page 40: ...lus signs The selections are listed below For more information contact your local ABB representative 3 Valid markings Possible markings are for example CE marking EAC marking UL marking RCM marking WEEE marking See chapter Technical data 4 Ratings of the converter 5 Number and frame size of the converter modules In the upper label for the ACS880 87LC converter there are four generator side convert...

Page 41: ...us TCP EtherNet IP adapter K467 Ethernet Modbus TCP PROFINET IO adapter K469 FECA 01 EtherCAT adapter module K473 FENA 11 Ethernet adapter module EtherNet IP Modbus TCP PROFINET Ethernet K464 NETA 21 remote monitoring tool EIP MB TCP Construction C129 UL design C143 Cooling connections right when looking the converter from the main breaker cubicle side C144 Cooling connections left when looking th...

Page 42: ...t 100 A included as standard G398 Auxiliary 3 phase power output 80 A included as standard G399 Auxiliary 3 phase power output 63 A included as standard G422 Bleeding valve Specialities P902 Customized described in Technical Appendix P911 Extended warranty Safety options Q951 Emergency stop stop category 0 Documentation language delivered set may include documents in English R701 German R707 Frenc...

Page 43: ...l installation 43 4 Mechanical installation Contents of this chapter This chapter describes the mechanical installation procedure of the wind turbine converter Safety instructions See chapter Safety instructions ...

Page 44: ...it to the floor and tightening the connections 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 to...

Page 45: ...NING Only use a heavy 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 center of gravity is high Move only in the upright position Moving Pulling Pushing ...

Page 46: ...oved the converter to its final installation location or near it 1 Cut the attachment clamps with side cutters and pull them away 2 Remove the fastening screws nails rivets and unpack the converter from the wooden package 3 Cut the plastic covering the converter with a carpet knife and remove it 4 Detach the converter from its platform lift the converter and remove the platform Max 60 ...

Page 47: ... code for ABB lift adapter bars is 3AUA0000154605 1 Attach the ABB lift adapter to the lifting bars on the roof 2 Attach the lifting sling to the ABB lift adapter lifting point 3 Lift steadily 4 Position the converter as near its final position as possible 5 Remove the ABB lift adapter and store it for later use ...

Page 48: ... 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 evenly divided 3 Lift steadily 4 Position the converter as near its final position as possible 5 Remove the lifting bars and refasten the roof bolts to retain the degree of protection of the cabine...

Page 49: ...a back to back design and thus you cannot install it with a longer side against a wall The converter must be installed 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 met...

Page 50: ...onverter to the floor through the holes in each flat bar at the base of the cabinet using M12 screws We do not recommend welding see section Electric welding on page 51 Internal cooling circuit For installations related to cooling see chapter Cooling and heating on page 132 ...

Page 51: ...h the converter With user defined cable entries take care of the degree of 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 cabin...

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

Page 53: ... 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 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 circuit breaker does not isolate the grid cable termin...

Page 54: ...ximately the converter DC bus voltage with a very short rise time This is the case with all converters employing modern IGBT technology The voltage of the pulses can be almost double at the generator terminals depending on the attenuation and reflection properties of the generator cable and the terminals This in turn can cause additional stress on the generator and generator cable insulation Moder...

Page 55: ... 57 Note When continuous conduit is employed shielded cable is not required Note When using a four conductor system 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 frame potential and causes current to ground through the generator bearings and shaft Th...

Page 56: ...to that which results from the application of this table Compared to a four conductor system the use of symmetrical shielded cable reduces electromagnetic emission of the whole converter system as well as generator bearing currents and wear The generator cable and its PE pigtail twisted screen should be kept as short as possible in order to reduce electromagnetic emission as well as capacitive cur...

Page 57: ...PR Copper 20 22 24 26 29 4000A 4132A 7 EPR Copper 20 22 24 26 29 Grid cables Converter type ACS880 87LC Cable type Conductor type Total quantity of parallel cables 500 kcmil 400 kcmil 350 kcmil 300 kcmil 250 kcmil 4000A 4021A 7 EPR Copper 21 24 26 29 32 4000A 4132A 7 EPR Copper 21 24 26 29 32 Symmetrical shielded cable with three phase conductors and a concentric PE conductor as shield The shield ...

Page 58: ...d of the converter is shown below It consists of a concentric layer of copper wires with an open helix of copper tape or copper wire The better and tighter the shield the lower the emission level and bearing currents A four conductor system three phase conductors and a PE conductor in a PVC conduit Corrugated cable with three phase conductors and a protective conductor or cable in EMT conduit A we...

Page 59: ...ground conductor bonded to the conduit on each side of the joint Bond the conduits also to the converter enclosure Use separate conduits for grid generator DC resistors and control wiring A dedicated ground cable is always required Note Do not run generator wiring from more than one converter in the same conduit Armored cable shielded power cable 6 conductor 3 phases and 3 ground type MC continuou...

Page 60: ...signals This type of cable is recommended for the pulse encoder signals as well Employ one individually shielded pair for each signal Do not use common return for different analog signals A double shielded cable is the best alternative for low voltage digital signals but single shielded twisted multipair cable figure b is also acceptable Run analog and digital signals in separate shielded cables R...

Page 61: ...le 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 Control cable ducts 90 min 500 mm 20 in Generator cable Grid cable Control cables min 200 mm 8 in min 300 mm 12 in...

Page 62: ...conditions are within the limits specified under Ambient conditions on page 113 No additional thermal protection devices are needed Protecting the converter against ground faults in the generator or generator cable Both the grid side converter and generator side converter are equipped with an internal ground fault protective function to protect them against ground faults in the converter itself th...

Page 63: ... the firmware manual Supplying power for the auxiliary circuits The converter is not equipped with an auxiliary voltage transformer Always connect an external auxiliary power supply For the power rating see section Auxiliary circuit current consumption on page 114 As standard the converter auxiliary circuit is to be supplied from the electrical power network through an external transformer The con...

Page 64: ...uous connect the incoming and outgoing shields PE conductors when the DTC generator control mode is in use make sure that it is not possible to open the contactor while the converter is in operation The contactor may be opened only after a stop command is given to the generator side converter Otherwise the contactor may be damaged Protecting the contacts of relay outputs Inductive loads such as re...

Page 65: ...llation 65 Install the protective component as close to the inductive load as possible Do not install the protective components at the terminal block 1 Relay outputs 2 Varistor 3 RC filter 4 diode 230 V AC 230 V AC 24 V DC 1 2 3 4 ...

Page 66: ...66 Planning the electrical installation ...

Page 67: ...apter do not 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 Do not make any voltage tolerance or insulation resistance tests for example hi pot or megger on any p...

Page 68: ...value at 25 C or 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 at the time of the measurement Integrated DC chopper and DC resist...

Page 69: ... 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 busbar terminals 3 Lead the grid cables busbars into the inside of the cubicle 4 Fasten the grid cables busbars to the grid connection terminals Connect the phase conductors to terminals L1 L2 and L3 Tighten the conductors to 70 N m 52 lbf ft...

Page 70: ...e converter module During installation cover the top of the module with plastic fabric etc WARNING Foreign objects inside the converter module can cause eg short circuit Injury or death or damage to the equipment can occur 4 When shielded cable is used Lead the cables into the inside of the cubicle Ground a shielded cable 360 at the lead through with an EMC cable gland to be supplied by the custom...

Page 71: ... the cover on top of the converter module WARNING The cover on top of the converter module can cause overheating Injury or death or damage to the equipment can occur 7 Refit the shroud removed earlier and close the door 8 Connect the generator end of the cable For minimum radio frequency interference and generator bearing current ground the cable shield 360 at the lead through of the generator ter...

Page 72: ...rnal power supply cable for the auxiliary circuit Power supply terminals for the auxiliary circuit are located in the lower part of the charging cubicle See the connection diagrams below and section Auxiliary circuit current consumption on page 114 ...

Page 73: ...ing the control cables Control cable connectors are located in the lower part of the auxiliary control cubicle see section Layout drawing on page 32 See the connection diagrams below and the circuit diagrams delivered with the converter ...

Page 74: ...74 Electrical installation Diagrams for the customer connections are presented below ...

Page 75: ...Electrical installation 75 optional Fast shutdown ...

Page 76: ...76 Electrical installation Default I O connection diagrams See the circuit diagrams delivered with the converter Connecting a PC See the start up guide ...

Page 77: ... the converter before start 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 mea...

Page 78: ...ge 110 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 section Tightening torques on page 110 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 customer acquired and...

Page 79: ...Maintenance 79 8 Maintenance Contents of this chapter This chapter contains preventive maintenance intervals and instructions ...

Page 80: ...R I R I R I R I R I R I R I R I R I R I R Checking cooling liquid pipe connections I I I I I I I I I I I I Checking the connections of fiber optic cables I I I I Checking tightness of cable and busbar terminals Tightening if needed P P P P Checking the quick connector of the converter module I I I I Checking the condition of contactors I I I I I I I I I I I I Checking the condition of the main con...

Page 81: ...ing liquid to be used is BASF Glysantin G30 or Valvoline Zerex G30 mixed with tapwater For more details see chapter Cooling and heating In case practical examples or specific tests carried with the above mentioned cooling mixture together with the cooling system materials the maintenance interval can be revised Note 2 The maintenance schedule of the main circuit breaker is according to maximum 1 0...

Page 82: ...ate a and the fasteners 4 pcs attaching the lower support plate b to the door plate 2 Remove the upper support plate a 3 Lift the grating and pull it away from the door 4 Remove the air filter mat 5 Place the new filter mat in the grating the metal wire side facing the door 6 Reinstall the grating in reverse order 1 2 3 4 5 3 a a b ...

Page 83: ... Check the tightness of the cable connections Use the tightening torques given in chapter Technical data Fans The lifespan of the cooling fans of the converter depend on the running time of the fan ambient temperature and dust concentration See the firmware manual for the parameter or actual value which indicates the running time of the cooling fan of the converter modules For resetting the runnin...

Page 84: ...he converter module 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 Ins...

Page 85: ...Maintenance 85 b c a Air flow direction 2 3 4 6 ...

Page 86: ...cle 3 Pull the shroud carefully out of the cabinet Observe the cable rail on top of the main circuit breaker when removing the shroud 4 Disconnect the wiring plug of the fan 5 Remove the fastening screws of the plate in front of the fans and remove the plate 6 Remove the fastening screws of the fan support plate and pull the support plate and the fan out 7 Remove the fastening screws of the fan gr...

Page 87: ...Maintenance 87 2 5 4 ...

Page 88: ...88 Maintenance 7 Arrow indicating the air flow direction 5 6 6 ...

Page 89: ...sources 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 control cubicle 3 Disconnect the wiring plug of the fan 4 Undo the four fastening screws of the fan 5 Pull the fan out 6 Install a new fan in reverse order Check that the air flow direction is co...

Page 90: ...90 Maintenance Air flow circulation b a ...

Page 91: ...sources and make sure it is safe to start the work See the safety instructions 2 Open the door of the LCL filter cubicle The upper cooling fans of the LCL filter cubicle are attached to the metal plate 3 Disconnect the wiring plug of the fan a 4 Undo the fastening screws of the fan b 5 Pull the fan out 6 Install a new fan in reverse order Check that the air flow direction is correct an arrow indic...

Page 92: ...92 Maintenance Air flow direction side view of the cubicle a b Upper cooling fans Door of the LCL filter cubicle ...

Page 93: ...y 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 Open the door of the LCL filter cubicle There are three cooling fans in the lower part of the cubicle 3 Disconnect the wiring plugs 3 pcs a of the fans and detach the thermostat B27 b 4 Remove the fastening screws M6 6 pcs c and...

Page 94: ...4 pcs d 6 Replace the fan 7 Install a new fan in reverse order Check that the air flow direction is correct an arrow indicating the direction is marked on the side of the fan In this case the air flow direction is upwards d 7 Arrow indicating the air flow direction 5 ...

Page 95: ...eath 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 The tightening torque for the M10 screws is 42 N m 31 lbf ft This figure is shown as an...

Page 96: ...h 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 The tightening torque for the M10 screws is 42 N m 31 lbf ft This figure is shown as an ex...

Page 97: ...ing Keep your fingers away 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 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 and make sure it is safe to start the wo...

Page 98: ...le cubicle 4 Remove the shroud supports 5 Remove the plastic covers in front of the fiber optic cables 6 Unplug the fiber optic cables and X50 connectors Carefully place the cables on top of the fan 7 Remove the pipe clamps from top tubes 4 4 4 4 5 5 5 6 6 6 7 7 ...

Page 99: ...elease it 9 Open two module support bolts from top 10 Open bottom liquid 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 8 9 9 12 10 11 11 11 11 11 12 ...

Page 100: ...100 Maintenance 13 Open Taptite M6 screw on the floor 14 Open the installation stand optional and place it in front of the module 13 14 ...

Page 101: ...Maintenance 101 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 ...

Page 102: ... 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 17 Pull the module out a bit 5 cm 20 in and install the lifting hook to the lifting hole 16 17 ...

Page 103: ...rs is 10 N m 7 4 lbf ft in room temperature around 20 C 68 F Capacitors The converter intermediate circuit employs film capacitors Their lifespan depends on the operating time of the converter loading and ambient temperature Capacitor life can be prolonged by lowering the ambient temperature Capacitor failure is usually followed by the converter module and module fuse failure or a fault trip Conta...

Page 104: ...out 2 Insert the new memory unit and fasten the screw Replacing the real time clock battery Replace the real time clock battery if the BATT LED is not illuminated when the control unit is powered See a in figure Replacement illustration on page 105 1 Undo the fastening screw and remove the battery 2 Insert the new battery according to figure Replacement illustration 3 Dispose the old battery accor...

Page 105: ...05 Replacement illustration See also chapter Control units of the converter Main circuit breaker For ABB SACE main circuit breaker maintenance refer to the manufacturer s instructions 1SDH001000R0002 A 2 1 A a a b c ...

Page 106: ...106 Maintenance ...

Page 107: ...he ACS880 87LC 4000A 4021A 7 and ACS880 87LC 4000A 4132A 7 Ratings Converter type ACS880 87LC Generator side converter ratings Grid side converter ratings Cos phi Pgen I2 Pgrid I1 Sn kW A kW A kVA UN 690 V 4000A 4021A 7 4302 4000 4325 4021 4806 0 9 4000A 4132A 7 4302 4000 4445 4132 4939 0 9 3AXD10000011539 ...

Page 108: ...y 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 is 40 C instead of 50 C instead of 5 current derating Type equivalence table Generator side converter ratings UN Nominal voltage see also section Grid specification on page 111 Pgen Typical generator power The power ratings apply at nom...

Page 109: ...gs Converter type ACS880 87LC AC fuses Type IN A rms Qty UN 690 V 4000A 4021A 7 Bussmann 170M6116 1250 15 4000A 4132A 7 Bussmann 170M6116 1250 18 3AXD10000011539 Converter type ACS880 87LC DC fuses Type IN A rms Qty UN 690 V 4000A 4021A 7 Bussmann 170M6151 1400 20 4000A 4132A 7 Bussmann 170M6151 1400 22 3AXD10000011539 Converter type ACS880 87LC Dimensions Weight Height Depth Width mm in mm in mm ...

Page 110: ...the cabinet at the bottom of the cabinet Tightening torques For the drawings and dimensions of the grid cable terminals see chapter Dimension drawings Converter type ACS880 87LC Losses Cooling data Noise Liquid Air Coolant quantity Mass flow tolerance 2 20 Pressure loss kW kW l l min kPa dBA UN 690 V 4000A 4021A 7 148 3 50 280 100 70 4000A 4132A 7 153 3 80 300 100 70 3AXD10000011539 Screw size Tor...

Page 111: ...AC converters This is indicated in type designation label as typical input voltage level 3 690 V AC 10 variation from the converter nominal voltage is allowed as default Frequency f1 50 5 Hz or 60 5 Hz Maximum rate of change 17 s Maximum allowable prospective short circuit current IEC 60439 1 UL 508 C 75 kA when protected by fuses given under Fuses According to UL 508C the converter is not rated f...

Page 112: ... also section Temperature derating on page 108 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 the operational condition is out of any environmental classifications and or corrosion class the expected lifetim...

Page 113: ...reezing of coolant is not allowed Above 45 C 113 F see section Derating on page 108 40 70 C 40 158 F 40 70 C 40 158 F Relative humidity 0 95 0 95 0 95 No condensation allowed Maximum allowed relative humidity is 60 in the presence of corrosive gases Contamination levels IEC 60721 3 3 IEC 60721 3 2 IEC 60721 3 1 No conductive dust allowed Boards with coating Chemical gases Class 3C2 Solid particles...

Page 114: ...ge semi gloss Color of the side panels RAL 9017 black semi gloss Busbars Tin or silver plated copper or aluminum Internal cooling circuit piping Aluminum 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 main parts of the con...

Page 115: ...complies with the standards below The compliance with the European Low Voltage Directive is verified according to standards EN 61800 5 1 EN 60204 1 2006 A1 2009 AC 2010 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 EN 60529 1991 Degrees of protectio...

Page 116: ...to 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 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 D...

Page 117: ... if the converter is used on such a network ETL marking cETLus according to UL marking is pending The converters are ETL certified in accordance with UL 61800 5 1 Adjustable Speed Electrical Power Drive Systems First Edition The converter provides overload protection in accordance with the National Electrical Code US and Canadian Electrical Code Canada See the firmware manual for setting Default s...

Page 118: ...signed to be connected to and to communicate information and data via a network interface 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 application of au...

Page 119: ...he 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 th...

Page 120: ...log input AI1 I current U voltage AI2 Mode selector for analog input AI2 I current U voltage D2D TERM Termination switch for drive to drive link D2D DICOM DIOGND Ground selection Determines whether DICOM is separated from DIOGND ie the common reference for the digital inputs floats 7 segment display Multicharacter indications are displayed as repeated sequences of characters U is indicated briefly...

Page 121: ...tic connection to converter modules 1 and 2 VxT transmitter VxR receiver V3T V3R V7T V7R Fiber optic connection to converter modules 3 7 BCU 12 22 only VxT transmitter VxR receiver V8T V8R V12T V12R Fiber optic connection to converter modules 8 12 BCU 22 only VxT transmitter VxR receiver SD CARD Data logger memory card for converter module communication BATT OK Real time clock battery voltage is h...

Page 122: ... digital filtering up to 8 ms Digital inputs outputs DIO1 and DIO2 XDIO 1 and XDIO 2 Input output mode selection by parameters 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 or other wave form cannot be used DIO2 can be configured as a 24 V level square wave frequency output See the firmware manual paramet...

Page 123: ...r pitch 5 mm wire size 2 5 mm2 Input voltage range 3 30 V DC Logic levels 0 5 V 1 17 V For the converter to start both connections must be 1 EMC immunity according to IEC 61326 3 1 Safe torque off output XSTO OUT Connector pitch 5 mm wire size 2 5 mm2 Control panel connection X13 Connector RJ 45 Cable length 3 m Ethernet connection XETH Connector RJ 45 SDHC memory card slot SD CARD Memory card typ...

Page 124: ...124 Control units of the converter ...

Page 125: ...Dimension drawings 125 11 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 ...

Page 126: ...126 Dimension drawings ...

Page 127: ...Dimension drawings 127 ...

Page 128: ...128 Dimension drawings ...

Page 129: ...eat generating electrical components 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 ...

Page 130: ...130 Cooling and heating Coolant OUT TE TE1 TE TE2 Coolant IN Generator side converter modules Choke 2 Choke 1 Generator side converter modules Grid side converter modules Grid side converter modules ...

Page 131: ...an be ordered as an option G422 The materials used in the cooling system are listed in Specifications on page 136 Coolant temperature control The temperature of the coolant in the internal cooling circuit must be kept within the limits specified in Specifications on page 136 Note that the minimum temperature depends on ambient temperature and relative humidity The following diagram shows an exampl...

Page 132: ...ling unit 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 directly to the coupling pipes on the side of the converter Lay liquid piping with extreme care Secure the pipes properly mechanicall...

Page 133: ... is usually near or at the cooling unit Bleeding and draining valves are not included in the standard delivery of the ABB converter bleeding valve is option G422 Observe the instructions given by the manufacturer of the cooling unit Pay special attention to filling up and bleeding the pumps properly as they may be damaged if operated when dry Draining propylene glycol into the sewer system is not ...

Page 134: ...f 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 and coolant according to section Freeze protection and corrosion inhibition on page 137 drain the cooling circuit again Cooling station control Instructions for liquid cooling control 1 After the transportation package is opened a The converter must be st...

Page 135: ...0 F above converter outside air The cooling liquid temperature minimum 25 C 77 F and maximum 50 C 122 F 5 During normal operation long period of time lack of electricity a Option 1 Back up power source to maintain 230 V AC for cooling unit and converter b Option 2 Follow points 2 c and 2 d ...

Page 136: ...nded 200 kPa maximum Base pressure denotes the pressure of the system compared with the atmospheric pressure when the cooling circuit is filled with coolant Maximum design pressure 500 kPa Recommended design maximum pressure 380 kPa Note Contact ABB if you need to rise the pressure over this limit The pressure difference must be within given limits to avoid malfunction due to excessive coolant flo...

Page 137: ...ARNING Operation at liquid temperatures below 0 C 32 F is not permitted even with antifreeze Liquid mixture quality The pH level of the coolant must not be manipulated by adding chemicals not specified in this document This may build up sediment in the liquid Tap water The use of drinking water without gas bubbles is allowed as follows The water must fulfill the requirements of the Council Directi...

Page 138: ...603 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 When 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 mino...

Page 139: ...onverter cooling circuit all cubicles 2 Switch on the auxiliary voltages Connect input voltage to the terminal X1 230 V AC UPS and 400V AC non UPS 3 Wait for the converter cabinet to warm up 4 If the temperature of the auxiliary control cubicle is 10 C the fans inside the converter cabinet start and speed up the warming process 5 Wait until the fans stop The temperature has risen enough in all par...

Page 140: ... described above the converter gives the heating and starting the pump requests to the liquid cooling unit when the cubicle temperature decreases below 10 C Heating request of the converter cabinet is wired to XDI 7 on the BCU control unit of the grid side converter If XDI 7 becomes 1 some parts of the converter cabinet are not warm enough In this case the customer needs to switch on the warming o...

Page 141: ...following diagrams show the heating control logic of the converter Note This is an overview diagram to help in understanding the description of the heating above See the delivery specific circuit diagrams for the actual wiring for each converter ...

Page 142: ...142 Cooling and heating ...

Page 143: ...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 ...

Page 144: ...abb com windconverters 3AUA0000120723 Rev D EN 2018 11 29 Copyright 2018 ABB All rights reserved Specifications subject to change without notice ...

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