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ABB PCS6000, User Manual

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ABB PCS6000 User Manual Download Page 11

INTRODUCTION, TERMS, TRADEMARKS AND RELATED DOCUMENTS

PRODUCT

PCS6000

DOCUMENT KIND

User manual

DOCUMENT ID.

3BHS600000 E40

REV.

G

LANG.

en

PAGE

11/114

1. Introduction, terms, trademarks and related 

documents

1.1 Equipment covered by this manual

This manual covers a standard converter and provides generic information on the 
converter. The manual does not claim to cover all variations and details of the converter, nor 
to consider all eventualities that may arise during installation, commissioning, operation 
and maintenance of the converter.

If the converter is adapted to specific customer needs or applications, and handling, 
installation and operation of the converter are affected by these modifications, 
information on these modifications is provided in the appropriate documentation (eg, 
layout drawings, wiring diagrams, technical data, engineering notes).

If information is required beyond the instructions in this manual, refer the matter to ABB.

1.2. Overview

This manual covers the standard PCS6000 equipment and provides generic information. 
The manual does not claim to cover all variations and details of the equipment, nor to 
consider all eventualities that may arise during installation, commissioning, operation and 
maintenance of the equipment.

If the equipment is adapted to specific customer needs or applications, and if handling, 
installation, and operation of the equipment are affected by these modifications, specific 
information is provided in the appropriate documentation (eg, layout drawings, wiring 
diagrams, technical data, and engineering notes) in the appendices.

Each person responsible for the transportation, installation, operation, commissioning, 
preventive maintenance or troubleshooting must have read and fully understood the 
corresponding chapters in this PCS6000 user's manual and in particular chapter 2, 

Important safety information

, page 19. These responsible persons must ensure that all 

involved personnel follows the relevant instructions from this manual.

Summary of Contents for PCS6000

Page 1: ... User manual OWNING ORGANIZATION ABB Switzerland Ltd DATE 2022 03 22 STATUS Approved SECURITY LEVEL Public DOCUMENT KIND User manual DOCUMENT ID 3BHS600000 E40 REV G LANG en PAGE 1 114 Copyright 2012 ABB All rights reserved ...

Page 2: ...ding but not limited to the installation of firewalls application of authentication measures encryption of data installation of antivirus programs and so on to protect these products the network its system and interfaces against security breaches unauthorized access interference intrusion leakage and or theft of data or information Any liability of ABB in this regard is excluded ABB may perform fu...

Page 3: ...afety information 19 2 1 Safety standards 19 2 2 Safety messages 19 2 3 Product safety labels 20 2 4 General safety instructions 21 2 5 The 7 steps that save lives 22 2 6 Possible residual risks 24 2 7 Important note main circuit breaker 26 2 7 1 Safety and protection requirements 27 2 7 2 Safety and protection requirements for the MCB 27 2 8 Maintenance recommendation 28 3 Product description 29 ...

Page 4: ...k lift truck requirements 56 4 2 7 Unpacking 57 4 2 7 1 Unpacking additional parts 59 4 2 8 Moving equipment to place of installation 59 4 2 8 1 Moving by crane 60 4 2 8 2 Moving by transport rolls 61 4 2 8 3 Disposal of packing materials 61 4 2 9 Transport conditions 62 4 3 Storage 62 4 3 1 Storage conditions 62 4 3 2 Storage and handling of spare parts 63 4 4 Disassembly and disposal of equipmen...

Page 5: ...8 1 Auxiliary cable entry 84 6 8 2 Auxiliary power supply connection 85 6 8 3 Control cable connection 87 7 Commissioning 89 7 1 Required qualification 89 7 2 Commissioning procedure 89 7 3 Commissioning checklist 89 7 4 Customer assistance 89 7 5 Customer acceptance 89 7 6 Commissioning checklists 90 7 6 1 Mechanical installation checklist 90 7 6 2 Electrical installation checklist 91 7 6 3 Main ...

Page 6: ...Log book 106 9 3 Preventive maintenance explanations 106 9 3 1 Visual inspection 106 9 3 2 Cleaning 106 9 3 3 Performance 107 9 3 4 Replacement of components 107 9 3 5 Maintenance schedule 107 10 Troubleshooting 109 10 1 Safety 109 10 2 General directives 110 10 2 1 Log book 110 10 3 Standard procedure for troubleshooting 110 10 4 Alarms and faults 111 10 4 1 Fault levels 111 10 4 2 Alarm and faul...

Page 7: ...12 Operator tools A GBU B and GBM C 36 Figure 3 13 WCU typical design 37 Figure 3 14 Typical HFM and FRM implemented in FIU 38 Figure 3 15 Typical BRU 39 Figure 3 16 CCU mounted to left side of cabinet 40 Figure 3 17 CCU Converter Control Unit typical design 40 Figure 3 18 Basic cabinet design 41 Figure 4 1 Type and dimensions of wood pallet 44 Figure 4 2 Roof beam placement 49 Figure 4 3 Packing ...

Page 8: ...le entry B 79 Figure 6 10 Grounding cam at a base frame with M12 bolt 81 Figure 6 11 Ground rail for cable shield connections 81 Figure 6 12 Grounding the grid side A and generator side B of a 1CL converter system 82 Figure 6 13 Grounding the generator side of the converter system of a 2CL converter system 83 Figure 6 14 Position of the auxiliary power terminals inside the CCU 85 Figure 6 15 Posit...

Page 9: ...ons 14 Table 1 2 Standards that are referred to in this document 17 Table 3 1 Overview of available BRUs 39 Table 6 1 Cable types and shielding method 75 Table 8 1 Local control binary indications controller output signals 98 Table 8 2 Local control binary commands controller input signals 98 Table 8 3 Local control commissioning ports 98 ...

Page 10: ......

Page 11: ...the instructions in this manual refer the matter to ABB 1 2 Overview This manual covers the standard PCS6000 equipment and provides generic information The manual does not claim to cover all variations and details of the equipment nor to consider all eventualities that may arise during installation commissioning operation and maintenance of the equipment If the equipment is adapted to specific cus...

Page 12: ...down and decommissioning of the PCS6000 is given chapter 5 Mechanical installation page 65 and chapter 6 Electrical installation page 67 specify the requirements for the installation site gives an overview of the foundation cabling cooling and other equipment and gives instructions on mounting the PCS6000 chapter 7 Commissioning page 89 provides information on preparing the device for commissionin...

Page 13: ...Data sheets for components A07 Upgrades and modifications A08 Fault handbook 1 5 Related documents Title ABB ID PCS6000 Service Manual 3BHS600000 E80 PCS6000 preventive maintenance schedule 3BHS600000 E88 PCS6000 product family water cooling unit operations and maintenance manual 11944677 ZAE Painting specification for ACS1000 ACS2000 ACS5000 and ACS6000 ACS6080 3BHS104301 E01 Mechanical and elect...

Page 14: ...Line BRU Braking Resistor Unit CCA Converter Cabinet CL Conversion Line CCU Converter Control Unit CT Current Transducer DC Direct Current DLU DC Link Unit EMC Electromagnetic Compatibility ESD Electrostatic discharge FCA Filter Cabinet FIU Filter Unit FRM Filter Reactor Module GBM Grid Breaker Module GBU Grid Breaker Unit GDM Generator Disconnector Module GEB Generator Breaker GRB Grid Breaker HE...

Page 15: ... experienced in unpacking and transporting heavy equipment 1 7 2 Mechanical installation The personnel must be qualified to prepare the installation site according to the site and equipment requirements and to perform the installation accordingly 1 7 3 Electrical installation Personnel must have a sound knowledge of the relevant electrical codes and specifications covering low and medium voltage e...

Page 16: ...responsibility of those in charge of the equipment to ensure that each person involved in the installation operation or maintenance of the equipment has received the appropriate training and has thoroughly read and clearly understood the instructions in this manual and the relevant safety instructions 1 9 Intended use of the equipment Those in charge of the converter must ensure that the equipment...

Page 17: ... 3 1 Classification of environmental conditions Classification of groups of environmental parameters and their severities Storage IEC 60721 3 2 Classification of environmental conditions Classification of groups of environmental parameters and their severities Transportation IEC 60721 3 3 Classification of environmental conditions Classification of groups of environmental parameters and their seve...

Page 18: ...ual DOCUMENT ID 3BHS600000 E40 REV G LANG en PAGE 18 114 1 11 Tools ABB offers various tool sets containing all necessary tools and equipment for installation commissioning and maintenance of the converter The content of the tool sets is described in the PCS6000 Service Manual 3BHS600000 E80 ...

Page 19: ... on or around the equipment Failure to do so can result in serious Injury or DEATH Keep for future reference This is the safety alert symbol It is used to alert you to potential physical injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury WARNING Indicate...

Page 20: ...on Figure 2 1 Product warning label examples label placement depends on the converter Additional safety labels including the following might also be provided 1 Danger label 2 Warning label 3 Caution label 4 Notice label Electricity warning This sign can also have additional text below it eg High voltage Hot surface Crushing of hands No access for people with active implanted cardiac device The mag...

Page 21: ...ety hazards 4 While working on the converter Wear hearing protection when a converter is running Do not step on the roof Do not install foreign objects on the roof 5 Before working on a water cooling unit WCU In addition to the safety instructions for working on a converter always read the WCU safety data sheet for relevant safety information eg the type of ion exchange resin and glycol 6 Before w...

Page 22: ...nal Protective Equipment PPE Decide of the appropriate work methods and initiate the Permit To Work PTW process 2 Clearly identify the work location and equipment Use your senses sight hearing and smell to identify problem areas Define the work area via barriers and barricading and label equipment Avoid distractions such as talking or texting on the phone 3 Disconnect all sources of supply and sec...

Page 23: ...nd short circuiting If this is carried out by the customer then the PICW must ensure that this equipment is properly earthed as a part of the integration verification and during step 7 when the PICW walks the PTW 6 Protect against adjacent live parts and take special precautions when close to bare conductors Determine minimum approach distances apply screening or shrouding and when applicable padl...

Page 24: ...correctly assembled or installed equipment Wrongly connected cables External influence on or damage of the equipment Wrong parameter settings Software errors Faulty hardware 3 Hazardous touch voltages can be present on converter system components which can be caused by Operation of the equipment outside the scope of the specifications External influence on or damage of the equipment Induced voltag...

Page 25: ...njuries from particles contamination electric shock hearing damage burns explosion due to hardware failure operation beyond specified limits unauthorized access No access to converter room or platform is allowed when the turbine is idling with open generator disconnectors or a 2CL converter is running in constricted operation Turbine idling speed shall be limited to a maximum of 30 of rated speed ...

Page 26: ...rsonnel and further damage to the equipment The MCB is located on the primary side of the converter transformer NOTE MCBs and protection relays are not included in the converter supply Figure 2 2 Converter system overview Typical MCBs devices Vacuum circuit breakers SF6 circuit breakers Fused contactors or motor control centers Dedicated protection relay Transformer or converter primary cable prot...

Page 27: ...ter must also be able to open the MCB at any time It is not permitted to interrupt the open and or trip command eg with a local remote switch in the MCB Closing control of the MCB when the MCB is in service position the converter must have exclusive control over closing the MCB ie local closing of the MCB is not permitted MCB maximum opening time cannot exceed the maximum time that is defined in t...

Page 28: ...ol voltage Upstream protection coordination scheme is provided which uses the breaker failure ANSI 50BF signal to automatically trip the upstream breaker in case the MCB does not open IMPORTANT The upstream breaker must open within the maximum safety trip time after a failure has occurred 2 8 Maintenance recommendation The MCB trip circuits should be checked annually 1 Short circuit occurs 2 Open ...

Page 29: ...ency converter that is ideal for highly demanding medium voltage applications The design allows maximum flexibility at different power ratings and also customized solutions involving a minimum prototyping and engineering effort Two main concepts are available 1CL configuration Single conversion line 2CL configuration Dual conversion line that allows you to operate the system in constricted mode ie...

Page 30: ...EV G LANG en PAGE 30 114 Figure 3 2 PCS6000 configuration examples Figure 3 3 PCS6000 configuration example 1 Inline 1CL 2 Back to back 2CL 1 CCU Converter control unit 2 FIU Filter unit 3 POU Power unit 4 GBU Grid breaker unit 5 DLU DC Link unit 6 WCU Water cooling unit 1 2 1 2 2 3 3 4 5 6 ...

Page 31: ...POU A POU contains three 3 level NPC phase legs with IGCTs The semiconductors are clamped into one stack A POU is controlled and supervised by the main circuit interface board that contains the control switching machine and the measurement interface Figure 3 4 POU 1 Cooling pipe 2 DC link capacitors 3 Control 4 Auxiliary supply 1 2 4 3 ...

Page 32: ... DLU contains the following sub assemblies Neutral point connection module Pre charging module Voltage limiting module dv dt filter DC link grounding isolator Generator disconnector module Figure 3 5 DLU 1 Generator disconnector module 2 dv dt filter module 3 DC link grounding isolator 4 Neutralpoint connection module 5 Voltage limiting module 1 2 3 4 5 ...

Page 33: ...mited period of time Normally an earth fault is detected and the converter switched off immediately A second function of the NCM is to discharge the DC Link via high resistance in the case that the VLM does not work properly Figure 3 6 NCM 3 2 2 2 Voltage limiting module VLM The VLM has an IGCT stack If the DC Link voltage exceeds a certain limit the VLM closes the current path through the braking...

Page 34: ...converter DC Link in case of service or maintenance work The DC Link grounding isolator is blocked in open position at DC Link voltages higher than 50 V The handle can be locked with a padlock in closed position to prevent unauthorized operation The 2CL converter has two DC Link grounding isolators one per conversion line The DC Link ground isolator is a two position switch Open position DC Link i...

Page 35: ...to the converter Open position generator is disconnected Ground position generator is grounded In case that the motor mechanism fails eg due to lost auxiliary power for the GDM an extension spin rod can be used to operate the GDM manually This rod is stored inside the unit Figure 3 10 GDM NOTICE If you need to operate the GDM manually be aware to turn the GDM in the correct direction A sticker sho...

Page 36: ...ounding is established by closing the circuit breaker with the three position switch set to ground position The GBM is placed in a GBU The switch can only be operated manually by a set of hand cranks Figure 3 11 Circuit breaker and three position switch Figure 3 12 Operator tools A GBU B and GBM C 3 2 3 1 dv dt filter module See section 3 2 2 3 dv dt filter module VFM page 34 1 Circuit breaker 2 T...

Page 37: ... cooling water circuit De ionizing the cooling water A soft starter for the cooling pumps is available as option The WCU can be specified for connection of the external heat exchanger on the top standard or bottom The WCU varies depending on the converter size Figure 3 13 WCU typical design 1 Inlet from re cooler on top 2 Expansion vessel optional 3 Cooling water pump 1 4 Outlet to re cooler on to...

Page 38: ...4 3 2 5 Filter unit FIU The FIU is an RLC filter tuned to fulfill the harmonic limits defined by the relevant grid standards Figure 3 14 Typical HFM and FRM implemented in FIU 1 Converter 2 Transformer 3 Highpass filter module HFM 4 Filter unit 5 RLC filter 6 Filter reactor module FRM LF SIN LF RF1 CF1 1 2 3 4 5 6 ...

Page 39: ...r different converter power ranges The BRU can be placed somewhere close to the converter A roof installation is possible The maximum cable length between converter and BRU is 10 m The monitoring control of the BRU resistor temperature is done with a temperature model on the main circuit interface The BRU varies depending on converter size and application Figure 3 15 Typical BRU Table 3 1 Overview...

Page 40: ...ell as the communication interfaces to the remote control hardware Figure 3 16 CCU mounted to left side of cabinet Figure 3 17 CCU Converter Control Unit typical design 1 24 48 VDC power supply and UPS 2 Main controller PEC 3 I O measurement interfacing 4 CT and VT interfaces 5 Mini circuit breakers 230 V AC 6 Slow I O 7 Customer interfacing 8 Cable entry 9 Fast I O 10 Local control equipment see ...

Page 41: ... Electromagnetic compatibility EMC has been achieved by applying an EMC sealing around the doors and on the rear and side panels The inside panels of the compartments are not painted because paint tends to reduce the effectiveness of metallic bonding which is paramount to successful EMC The joining surfaces of two transport units are equipped with EMC sealing strips The cabinet doors and the inter...

Page 42: ...All transport units are fitted with lifting lugs for a crane that must be used to position the units Safety labels The standard language of the labels is English however other languages can be ordered The label design is based on the relevant ANSI and ISO standards see section 2 3 Product safety labels page 20 Safety labels are attached to the converter doors to alert personnel of potential hazard...

Page 43: ... available for the PCS6000 Foil wrapped and wood pallet Packing for land transportation page 44 Foil wrapped and wood box sea transportation Before you begin read and understand the general safety instructions in chapter 2 Important safety information page 19 CAUTION Danger of collapse DO NOT stand on the converter modules or the roof of the control cabinets NOTICE Converter components can be dama...

Page 44: ...he wood pallets must fulfill the following requirements Designed for transport by forklift Reusable Board thickness approximately 5 cm Cross section height 16 cm squares Total pallet length approximately 30 cm longer than the length of the cabinet Total pallet width approximately 60 cm wider than the width of cabinet Figure 4 1 Type and dimensions of wood pallet 1 Total pallet width 2 Cabinet widt...

Page 45: ...he pallet to the packing area with a forklift truck and position the crane with 2 slings over the converter cabinet 2 Apply edge protectors at the top of the cabinet and attach the crane slings to the front and rear eyebolts of the converter NOTICE Ensure that the edge protectors are under the slings 3 Lift the converter cabinet with the crane and lower it onto the pallet ...

Page 46: ...he barrier is created by wrapping the cabinet front back and sides with polyethylene PE film minimum 0 12 mm thick 1 Align the film vertically to the back wall of the converter with the excess foil at the top and then attach the film with several pieces of no residue tape NOTE Start at the back of the converter and continue to the front 2 Apply tape to the vertical edge of the overlap where the 2 ...

Page 47: ...en PAGE 47 114 3 Drape another sheet of PE film evenly over the top of the cabinet 4 Fold the film down on the left and right sides of the cabinet and attach each side flap diagonally to the side wall with tape 5 Fold the film down on the front and back sides of the cabinet and attach the film horizontally with tape ...

Page 48: ...apping machine next to the cabinet 2 Attach an end of the film to the pallet start the wrapping machine and adjust the tension on the control panel of the machine to 20 22 units IMPORTANT During the first pass wrap the film under the cabinet If necessary adjust the tension of the film to avoid rips on the pallet edges 3 When the machine starts to wrap the cabinet from top to bottom increase the fi...

Page 49: ...net to the pallet 1 Place 2 support beams 1 at least 60 cm in from each end of the cabinet roof and then slide the main beams 2 over the support beams NOTICE Avoid obstructions when you place the beams The mains beam must remain within the pallet footprint gray Figure 4 2 Roof beam placement 2 Secure the converter cabinet to the pallet by running band strapping through the base of the pallet and o...

Page 50: ...g a BRU to the pallet 1 Place 2 edge protectors on top of the BRU over the front and back edges at least 30 cm in from each end 2 Secure the BRU to the pallet with polypropylene straps 3 At each end of a strap make a 10 cm loop thread the loop through the center of a buckle and around one the buckle legs before tightening with a tensioner ...

Page 51: ... of the cabinet and the inside packaging have to be cushioned to avoid damage to the film penetration resulting in a loss of the vacuum protective atmosphere Desiccants according to DIN 55474 shall be distributed inside the packed device 4 2 2 4 Humidity indicator If desiccant with a barrier film is used for packaging ABB recommends using a humidity indicator for a storage period of more than 12 m...

Page 52: ... 3 Packing overview 1 Strutting wood bar and plastic compound corners 2 Steel strapping 3 Fixation of the converter component against sliding Ethafoam pad 4 Plastic compound cushioning 5 Rain shelter 6 Component packed in sealed PE or aluminum barrier film 7 Inspection hole for controlling the indicator 8 Humidity indicator 1 2 3 4 5 6 7 8 ...

Page 53: ...r other such handling must be avoided Keep dry Cargoes bearing this symbol must be protected from excessive humidity and must be stored under a cover If particularly large or bulky packages cannot be stored in warehouses or sheds they must be carefully covered with tarpaulins Center of gravity This symbol is intended to provide a clear indication of the position of the center of gravity The meanin...

Page 54: ...onents Loading area is to be checked on leakage and cleanliness ABB will not accept any liability unless the damage is properly reported Use damage description report at the end of the chapter In order to avoid damage to the equipment do not remove the packing before moving the equipment to the place of installation NOTICE Converter components can be damaged during transportation Metallic dust in ...

Page 55: ...ng position In order to avoid any buckling of the transport frame and damage of the PCS6000 due to excessive pressure the maximum angle between the hanger and the vertical line base frame may not exceed 30 If this angle should be exceeded due to a low ceiling height a straddle carrier shall be used Figure 4 4 Loading and unloading in line PCS6000 with suspension beam CAUTION Danger of collapse DO ...

Page 56: ... used that fulfills the following criteria Load capacity Fork length Entry width Figure 4 5 Typical lifting with fork lift truck top In line layout bottom back to back layout CAUTION Risk of tipping Forks may only be applied at the longitudinal side Fig 4 5 The distance a between the forks must be more than 1500 mm Fork lift truck may only be driven at walking speed Length and entry width must hav...

Page 57: ...diately contact the responsible project management at ABB 2 Remove the top of the crate In case of foil packaging remove all packaging material carefully Do not use sharp or pointed tools to open the packaging Continue with Step 7 3 Remove the front rear and side walls of the crate NOTICE DO NOT take away the wood pallet when moving the cabinet by forklift 4 Check the cabinets for transport damage...

Page 58: ... Figure 4 6 Unpacking the equipment 5 Check the condition of any accompanying equipment 6 Compare the complete delivery with the purchase order IMPORTANT If parts are missing contact immediately the shipping company and the local ABB service organization 1 Top of crate 2 Rear wall 3 Side wall 4 Front wall 5 Wood pallet 1 2 3 3 4 5 ...

Page 59: ... unpacking move the equipment to the place of installation Crane recommended Fork lift truck IMPORTANT The equipment must always be placed on a level surface Make sure that the equipment cannot topple while being moved NOTICE Risk of component damage Electrostatic discharge ESD can damage electronic boards and components Handle all electrical components with care DO NOT touch printed circuit board...

Page 60: ... eyebolts attached to the base frame The equipment must be transported in such a way that it does not suffer any shocks Always use a suspension beam for lifting as shown in Fig 4 7 Ropes of insufficient strength and length are not allowed when lifting the equipment by crane Figure 4 7 Moving PCS6000 with suspension beam CAUTION Risk of stumbling Remove the protruding eyebolts after moving equipmen...

Page 61: ...et must be removed when using transport rolls Figure 4 8 Moving PCS6000 by transport rolls 4 2 8 3 Disposal of packing materials Parts of the packaging material can be re used Dispose of the packaging material according to local regulations Polyethylene foil Wood pallets Wood box Plywood Desiccant CAUTION Risk of serious injury Tipping and tilting must be avoided Equipment must always be transport...

Page 62: ... to authorized personnel In order to minimize the risk of damage all equipment must be easily accessible for inspection and or repairs Equipment must be stacked in such a way that no item can be damaged by the weight of any other part Firefighting equipment must be present and easily accessible The storage room must be kept clean at all times and the accumulation of waste and old packing material ...

Page 63: ...hock Protected against dust and sand Protected against vermin and insects Free of corrosive gases salt or other impurities that could damage electronic equipment and boards Dry no condensation 4 4 Disassembly and disposal of equipment Dispose of the following components according to local regulations Batteries Capacitors Printed circuit boards Electronic components NOTICE Electrostatic discharge E...

Page 64: ......

Page 65: ...pendix A03 Electrical Drawings In order to ensure a safe and faultless installation a careful planning and preparation is essential Ensure adequate lighting and access to the place of installation All installation work must be carried out by qualified personnel according to the site and equipment requirements and in compliance with local regulations NOTICE Keep dust free Dust inside the PCS6000 ca...

Page 66: ...5 4 Concluding work 5 4 1 Damage to paintwork If any damage to paintwork has occurred during transport and installation the damaged spots must be touched up before commissioning the equipment Only polyurethane paints may be used for touching up damaged paintwork since only these are guaranteed to adhere properly to the original coatings Small chips and scratches can be touched up using a fine hair...

Page 67: ...g items Electrical installation instruction of MV connection page 76 Grounding the converter system page 80 Auxiliary connection page 84 All installation work must be carried out by qualified personnel according to the site and equipment requirements and in compliance with local regulations DANGER Hazardous voltage Handling live parts can result in DEATH or SERIOUS INJURY When located installed an...

Page 68: ... individual components Measures for achieving electromagnetic compatibility are defined on the basis of the EMC analysis 6 3 2 EMC Zone Concept IEC 61800 3 proposes to subdivide the installation into different EMC zones Fig 6 1 shows the generic EMC zone concept according to this standard The PCS6000 converter system is designed in accordance with IEC 61800 3 The applicable zones are Zone 0 power ...

Page 69: ...ements 6 4 1 Power cables For information on the requirements for power cables ground cable and equipotential bonding conductor see Power cables engineering guideline 3BHS542290 E01 Zone 0 Zone 1 Zone 4 Zone 3 Zone 2 Industrial power supply Circuit breaker Converter transformer Busbar Converter Supervisory control protection User s control system Cooling system Harmonic filter Auxiliary system Gat...

Page 70: ...arrying capacity of cables is defined for sinusoidal waveforms For operation with non sinusoidal waveforms the current carrying capacity is reduced by the rating factor The rating factor covers only converter operation The ampacity rating of the cable shall consider derating factors of the cable in accordance with maximum expected ambient temperature and any other factors required by local electri...

Page 71: ... conductor an additional equipotential bonding conductor is required This conductor is laid in parallel to the phase conductor 6 4 2 Grid side Topic Value Unit Comment Number of phases 1 3 1CL 2 3 2CL pcs pcs Connection Pfisterer P3PS panel socket Number of connections 2 or 3 sockets phase Plugs for up to two cables can be connected For more information see the project specific documentation du dt...

Page 72: ...ctions 2 or 3 phase Plugs for up to two cables can be connected For more information see the project specific documentation du dt 2 5 kV At converter terminals Rated voltage 3300 V Insulation U0 U 6 10 kV IEEE 5 8 kV Rating factor 0 85 To cover converter operation Maximum length 100 m Single phase current 3 kArms Maximum 3 s Topic Value Unit Comment Number of phases 2 per resistor 2 resistors per ...

Page 73: ... phase cable without neutral wire is required for the supply voltage of the synchronization transformer NOTICE Risk of false signals DO NOT lay control cables parallel to the power supply cables If this cannot be avoided maintain a minimum distance of 30 cm between the control and power supply cables Cross control and power supply cables at an angle of 90 Signal type Cable type Cross sectional are...

Page 74: ...als and are therefore completely shielded including their connectors Class 2 This class includes cables which conduct slightly EMC sensitive signals e g primary transformer signals cables for slow communication e g RS422 RS485 and digital input output signals These cables must also be shielded Class 3 This class particularly includes supply lines for devices low voltage AC or DC Class 4 This class...

Page 75: ...uence as small as possible 6 5 1 Summary Table 6 1 summarizes the individual cable types and where applicable their shielding and its connection 1 Class 1 cables 2 Class 2 cables 3 Class 3 cables 4 Class 4 cables Table 6 1 Cable types and shielding method Use Class Shield Shield connection Installation type Signal cable to and from switchgear CT VT 2 Yes On both sides Auxiliary power supply cable ...

Page 76: ...PLUG size P3 has an integrated code system Only connectors and sockets with the same code fit together The rotation angle is defined by the position of the panel socket flange The coding for all connections is AF01 This code is part of the plug part number Figure 6 3 Layout of panel socket with coding AF01 IMPORTANT The Pfisterer PLUG connectors that are described in this section are not part of s...

Page 77: ... which can be connected to the installed panel sockets Straight connector Type P3SC Number 305 015 AF01 Nominal current 800 A Cable cross section 70 to 240 mm2 Figure 6 4 Details of the Pfisterer PLUG straight connector Elbow connector for 1 cable Type P3EC1 Number 305 322 AF01 Nominal current 800 A Cable cross section 70 to 240 mm2 Figure 6 5 Details of the Pfisterer PLUG elbow connector for 1 ca...

Page 78: ...Pfisterer PLUG connector details P3SC This section describes details about the straight connector type P3SC In principle the given information is valid for the other connector types described above Figure 6 7 Schematic drawing of tailoring a Pfisterer PLUG connector 1 Contact 2 Housing 3 Strain relief 4 Gasket 5 Free area approximately 10 mm 6 Assembled lug 7 Screen weave braid 8 Outside mantle 9 ...

Page 79: ...n systems The power connections are made with Pfisterer plugs on the back or on the top of the cabinet The grid side connections are on the GBU and the generator side connections are on the DLU Figure 6 8 DLU and GBU rear cable connections A and rear cable entry B Figure 6 9 DLU and GBU top cable connections A and top cable entry B A B A B ...

Page 80: ...ciently high current carrying capacity to enable the dissipation of any fault currents that occur so that no hazardous voltages can result between two simultaneously accessible metal parts According to Schaltanlagen ABB Calor Emag Taschenbuch 10th edition chapter 5 3 3 the minimum cross section of a ground conductor should be defined as follows 1 With 16 2 kA initial short circuit current and 0 5 ...

Page 81: ...to chassis potential at the base frame as shown in Fig 6 10 The shields of the power cables are connected to the grounding bars close to the phase connectors as shown in Fig 6 11 External grounding cables must be connected from the main ground PE of the installation to the converter Figure 6 10 Grounding cam at a base frame with M12 bolt Figure 6 11 Ground rail for cable shield connections ...

Page 82: ...or side B of a 1CL converter system 1 Transformer or busbar 2 System ground 3 Cable shield 4 Cable armor 5 Equipotential bonding conductor 6 Ground cable 7 Grid side converter 8 Generator side converter 9 Generator L1 L2 L3 PE U1 V1 W1 FE 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 L1 L2 L3 PE 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 L1 L2 L3 FE FE PE 1 2 3 4 5 6 3 4 5 6 7 8 A B 9 ...

Page 83: ... System ground 3 Cable shield 4 Cable armor 5 Equipotential bonding conductor 6 Ground cable 7 Grid side converter 8 Generator side converter 9 Generator U2 V2 W2 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 L1 L2 L3 2L1 2L2 2L3 FE PE PE U1 V1 W1 PE PE 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 FE U2 V2 W2 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 L1 L2 L3 2L1 2L2 2L3 FE U1 V1 W1 PE PE 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2...

Page 84: ... these openings can be used to insert auxiliary cables into the cabinets Cable entry systems provide a convenient method to insert tailored cables of a wide range of cable diameters into cabinets This is done with slotted rubber inlays which can be placed around the cable slid into a two piece frame and then mounted to a precut opening IMPORTANT Cable entry systems described in this section are no...

Page 85: ...n the bottom of the CCU The auxiliary power supply cables shall be three phase cables with separate neutral separate PE and screen They will be connected directly to the terminals of an individual main switch The screen shall be connected to the grounding rail in each unit Figure 6 14 Position of the auxiliary power terminals inside the CCU 1 Auxiliary power UPS 2 Auxiliary power without UPS 3 Aux...

Page 86: ...recut openings for the auxiliary power and control cables The openings suit for common cable entry systems and are covered with a blind lid For more information about cable entry systems see section 6 8 1 Auxiliary cable entry page 84 Figure 6 15 Position of the cutouts for cable entry into the CCU 1 3AC400V auxiliary entry MCTs 24 pole cutout 2 MCTs 24 pole cutout 1 2 2 2 2 ...

Page 87: ...lled on the bottom of the CCU There is only a limited number of control cables required All cables can be entered through MCTs at the bottom of the CCU The openings for the cables must apply according to the local situation Cable protection eg glands must be provided by the customer All control cables have to be connected inside the CCU Figure 6 16 Position of the control cable terminals inside th...

Page 88: ...ELECTRICAL INSTALLATION PRODUCT PCS6000 DOCUMENT KIND User manual DOCUMENT ID 3BHS600000 E40 REV G LANG en PAGE 88 114 ...

Page 89: ... for commissioning Reviewing and completing the items in the commissioning checklist before the commissioning personnel arrive on site will help to achieve this During the commissioning period the customer is requested to provide qualified personnel for assistance who are Experienced with medium and low voltage equipment and with the local safety regulations Familiar with the driven process Author...

Page 90: ...gned according to layout drawing if delivered in several transport units and installed according to the instructions in this user manual 3BHS600000 E40 2 Converter is securely fixed to the floor 3 Roof attachments are installed if applicable 4 External water piping is completed and pipes are flanged to the converter 5 External cooling system is ready for operation 6 Visual inspection No badly affi...

Page 91: ... 6 Ground cable of the converter is securely connected at both ends 7 Cable armor and screens of power supply cables are connected to the ground busbar 8 All power cables plugs are mounted and connected to the converter 9 CTs and VTs are selected and installed according ABB specification 10 Overriding Control is prepared and tested for starting operation emergency sequences for commissioning and f...

Page 92: ...ff loop is tested 7 6 4 Input transformer checklist 1 Transformer is selected and installed according ABB Specification 2 Grounding is completed 3 Transformer auxiliaries eg dehydrating breathers cooling protection devices are ready 4 Protection devices eg door locks are tested and in operation 7 6 5 Generator checklist 1 Generator is installed aligned and alignment protocol available 2 Grounding ...

Page 93: ... converter 2 Low voltage is available for startup of converter 7 6 8 Miscellaneous checklist 1 Sufficient number and correct type of spare parts available 2 Sufficient quantity of deionized water according is available see Appendix C Mechanical drawings 3 A health and safety plan is created and available Site specific introduction if required is planned and will be provided to the commissioning pe...

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Page 95: ... 01 Control Interface and Operation Description 8 1 Operation conditions As soon as the converter is unpacked the environmental conditions for operation apply Between unpacking and first operation of the PCS6000 converter ABB suggests to take the following precautions Weekly visual check of the PCS6000 converter Annual capacity check of batteries according EN 50272 1 2001 With the first fill of th...

Page 96: ...as the auxiliary voltage is switched on or when the EMERGENCY OFF button is released even if the PCS6000 is de energized Switch off the corresponding motor protection switches see diagrams contained in the cabinet specific documentation to shut down the cooling system EMC performance must be maintained at all time All fastening screws must be mounted and tightened and the doors of all cabinets mus...

Page 97: ...faces are provided on the side of the CCU to allow general status diagnostic and operations Figure 8 1 Local control equipment 1 Application specific indicator 2 Key switch with application specific function 3 Lockout Tagout interlocking keys 4 Grid side voltage free 5 Grid grounded 6 Key release 7 EMERGENCY OFF 8 Commissioning ports 9 Generator side voltage free 10 Generator grounded 1 2 3 3 4 5 ...

Page 98: ...4 Operation Interface Documents Control Interface and Operation Description for detailed information on the control system and interfaces Table 8 1 Local control binary indications controller output signals Signal name Hardware Remarks Application specific Red LED lamp Grid Breaker CLOSED Red LED lamp DC LINK GROUNDING ISOLATOR CLOSED Yellow LED lamp DC LINK GROUNDING ISOLATOR RELEASED Yellow LED ...

Page 99: ... in the converter The losses of the pump go almost 100 into the water and the water heats up the converter inside The 3 start conditions are always fulfilled The converter can immediately go in to production mode If the auxiliary voltage was switched off for a long time eg before commissioning or service and the converter was cooled down to low temperatures the converter cannot be started immediat...

Page 100: ...T2 and the humidity limit switch H1 monitors the dew conditions inside the converter control unit IF the temperature stays below the limit setting OR the humidity stays above the limit setting the feeding of the auxiliary power to all other components of the Control Unit stays OFF IF the temperature stays above the limit setting AND the humidity stays below the limit setting the feeding of the aux...

Page 101: ...nd other objects are left in any of the units 2 Check that the grid is energized 3 The Anti dew startup sequence release for converter start See section 8 5 Anti dew startup sequence page 99 4 Check that the auxiliary power supply of the PCS6000 is switched on See Wiring Diagrams units in Appendix A03 Electrical drawings for project specific details 5 Check that the water cooling system is ready f...

Page 102: ...LED does confirm that the converter DC link is grounded and it is safe to work The ISOLATOR RELEASED LED confirms that the solenoid coil is released to connect the DC link to ground If the LED is off the DC link is charged and the handle cannot be turned towards the grounded position 10 If applicable Check that the grid grounding isolator is open and the grid disconnectors are closed IMPORTANT Gri...

Page 103: ...lication NOTE The emergency off status is signalized to the overriding controller For more information refer to the operation and interface documents in the appendix Release the EMERGENCY OFF button and reset the trip according to section 8 10 1 Alarm and trip reset page 104 Figure 8 4 Releasing EMERGENCY OFF button DANGER Hazardous voltage The PCS6000 contains no user operable parts inside the me...

Page 104: ...by means of a trip The start is prevented 8 10 1 Alarm and trip reset Press the ACKNOWLEDGE ALARM or ACKNOWLEDGE TRIP function key or select the appropriate command from remote control to reset all pending alarms and trips If an alarm or fault cannot be reset the original alarm or fault cause might still be present Ensure that the cause is removed and press the ACKNOWLEDGE ALARM or ACKNOWLEDGE TRI...

Page 105: ...frequency converter there is still voltage on the auxiliary energy distributor of the converter control system There can also be external auxiliary and control voltages eg of measuring circuits even if the internal auxiliary power supply is switched off Before doing any work on these circuits make sure that the corresponding external voltage sources are switched off and secured according to the sa...

Page 106: ...f power connections and visual checking Dust built up inside the converter room and inside the converter Signs for overheated components wires cables or busbars Corrosion on circuit boards connectors or busbars Appropriate fastening of plugs cables wires and their connections 9 3 2 Cleaning Cleaning is necessary if dirt or dust accumulation also called fouling occurs within the converter This coul...

Page 107: ...cement means exchange of components as part of the maintenance schedule or as a consequence of performed inspection see section 9 3 1 Visual inspection page 106 or performance checks see section 9 3 3 Performance page 107 9 3 5 Maintenance schedule Carry out all maintenance tasks according to the preventive maintenance schedule and the applicable service instructions on time and at the stated inte...

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Page 109: ...e is still voltage on the auxiliary energy distributor of the converter control system There can also be external auxiliary and control voltages eg of measuring circuits even if the internal auxiliary power supply is switched off Before doing any work on these circuits make sure that the corresponding external voltage sources are switched off and secured according to the safety rules After complet...

Page 110: ...follow exactly the instructions in the fault handbook Appendix A09 Fault handbook for fault finding and troubleshooting DO NOT attempt any repair work on the PCS6000 beyond these instructions Before starting to troubleshoot carefully read the warnings in section 10 1 Safety page 109 If the problem cannot be solved contact the authorized service engineer In case further support is required contact ...

Page 111: ...error is still pending call ABB service 10 4 Alarms and faults 10 4 1 Fault levels For a description of the various fault levels and error message reset see section 8 10 Alarm and fault handling page 104 and refer to Appendix A04 Operation and interface documents 10 4 2 Alarm and fault messages Appendix A09 Fault handbook provides a list of all alarm and fault messages and information on possible ...

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Page 114: ...rasse 66 CH 5400 Baden Switzerland new abb com power converters inverters wind turbines Copyright 2012 ABB All rights reserved The information in this document is subject to change without notice 3BHS600000 E40 Rev G 2022 03 22 114 ...

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