Related Manuals for ABB ACS880-87LC-4000A/4021A-7
Summary of Contents for ABB 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 Drive composer Start-up and maintenance PC tool 3AUA0000094606 user’s manual Manuals for I/O extension modules, fieldbus adapters, etc. Other documents Circuit diagrams set Fieldbus interface description Firmware release note with the download instructions For manuals, contact your local ABB representative.
- Page 3 Hardware manual ACS880-87LC-4000A/4021A-7 and ACS880-87LC-4000A/4132A-7 wind turbine converters Table of contents 1. Safety instructions 4. Mechanical installation 6. Electrical installation 2018 ABB Oy. All Rights Reserved. 3AUA0000120723 Rev D EFFECTIVE: 2018-11-29...
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Page 5: Table Of Contents
Table of contents 1. Safety instructions Contents of this chapter ..........11 Use of warnings and notes . - Page 6 Unpacking ............46 Lifting the converter – ABB lift adapter bars (customer variant) are in use ..47 Lifting the converter .
- Page 7 6. Electrical installation Contents of this chapter ..........67 Checking the insulation of the assembly .
- Page 8 Auxiliary circuit current consumption ........114 ACS880-87LC-4000A/4021A-7 and ACS880-87LC-4000A/4132A-7 ... 114 UPS supply .
- Page 9 Providing feedback on ABB Drives manuals ....... . . 143...
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Page 11: Safety Instructions
Safety instructions 11 Safety instructions Contents of this chapter This chapter contains the safety instructions which you must obey when you install and operate the converter, and do maintenance on the converter. If you ignore the safety instructions, injury, death or damage can occur to the converter, the generator or other adjoining equipment. -
Page 12: General Safety In Installation, Start-Up And Maintenance
12 Safety instructions General safety in installation, start-up and maintenance These instructions are for all personnel that install the converter and do maintenance work on it. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. •... -
Page 13: Electrical Safety In Installation, Start-Up And Maintenance
Safety instructions 13 Note: • Only authorized persons are allowed to repair a malfunctioning converter. Electrical safety in installation, start-up and maintenance Precautions before electrical work These instructions are for the qualified electricians who do work on the converter, generator cable or generator. -
Page 14: Additional Instructions And Notes
14 Safety instructions WARNING! If the measurement requires removal or disassembly of shrouding or other cabinet structures, obey the local laws and regulations applicable to live working (including – but not limited to – electric shock and arc protection). 6. Install temporary grounding as required by the local regulations. 7. -
Page 15: Fiber Optic Cables
Safety instructions 15 Fiber optic cables WARNING! Obey these instructions. If you ignore them, equipment malfunction and damage to the fiber optic cables can occur. • Handle the fiber optic cables with care. • When you unplug the cables, always hold the connector, not the cable itself. •... -
Page 16: Opening And Disconnecting The Main Circuit Breaker
16 Safety instructions Opening and disconnecting the main circuit breaker These instructions are for the qualified electricians who do work on the converter, generator cable or generator. WARNING! If you are not a qualified electrician, do not proceed or do any installation or maintenance work. - Page 17 Safety instructions 17...
- Page 18 18 Safety instructions...
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Page 19: Disconnecting The Charging Circuit From The Main Circuit
Safety instructions 19 Disconnecting the charging circuit from the main circuit WARNING! If you are not a qualified electrician, do not proceed. 1. Make sure that you have opened the main circuit breaker (Q1). See section Opening and disconnecting the main circuit breaker on page 16. -
Page 20: Disconnecting The External Auxiliary Power Supply
20 Safety instructions Disconnecting the external auxiliary power supply WARNING! If you are not a qualified electrician, do not proceed. 1. Make sure that you have opened the main circuit breaker (Q1). See section Opening and disconnecting the main circuit breaker on page 16. -
Page 21: Grounding
Safety instructions 21 Grounding These instructions are intended for all who are responsible for the grounding of the converter. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur, and electromagnetic interference can increase. -
Page 22: Work On The Liquid Cooling System
22 Safety instructions Work on the liquid cooling system These instructions are intended for all who are responsible for installation and maintenance work of the liquid cooling system of the converter. WARNING! Obey these instructions. If you ignore them, injury or damage to the equipment can occur. -
Page 23: Introduction To The Manual
Introduction to the manual 23 Introduction to the manual Contents of this chapter This chapter describes the intended audience and contents of the manual. It also contains a flowchart of steps in checking the delivery, installing and commissioning the wind turbine converter. -
Page 24: Contents Of The Manual
24 Introduction to the manual Contents of the manual • Safety instructions • Operation principle and hardware description • Mechanical installation • Planning the electrical installation • Electrical installation • Installation checklist • Maintenance • Technical data • Control units of the converter •... -
Page 25: Quick Installation, Commissioning And Operation Flowchart
Introduction to the manual 25 Quick installation, commissioning and operation flowchart Task Plan the installation. Check: ambient conditions, Technical data, page ratings, required external cooling circuit arrangements, Planning the electrical installation, page compatibility of the generator, power cable connection, Option manuals (if optional equipment is included) etc. -
Page 26: Terms And Abbreviations
DC link capacitors Energy storage which stabilizes the intermediate circuit DC voltage. DDCS Distributed drives communication system; a protocol used in optical fiber communication Direct torque control; a generator control method by ABB. Electromagnetic compatibility FCAN Optional CANopen® adapter module FCNA Optional ControlNet™... - Page 27 Introduction to the manual 27 Term/abbreviation Explanation Frame (size) Refers to converter modules that share a similar mechanical construction, for example: • frame 5×R9iLC + 6×R9iLC includes five R9iLC generator-side converter modules and six R9iLC grid-side converter modules. Generator-side The converter part that is connected to the generator stator and controls the converter generator operation.
- Page 28 28 Introduction to the manual...
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Page 29: Operation Principle And Hardware Description
Operation principle and hardware description 29 Operation principle and hardware description Contents of this chapter This chapter describes the operation principle and the construction of the wind turbine converter. Operation principle The ACS880-87LC is a four-quadrant, cabinet-mounted liquid-cooled converter intended for full power conversion turbines with an induction generator or a permanent magnet generator. -
Page 30: Generator Control
30 Operation principle and hardware description Generator control The generator power flows through 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: Overview Diagram Of The Wind Turbine Converter
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: Layout Drawing
32 Operation principle and hardware description Layout drawing Layout of the wind turbine converter is shown below. Front view... - Page 33 Operation principle and hardware description 33 Description Generator-side converter cubicles [+11.1, +11.2] Main breaker cubicle [+01.6] Charging cubicle [+01.6] Coolant out (option +C144 cooling connectors left) Generator-side converter modules [T5] DC fuses [F5] Generator cable terminals [U2, V2, W2] Main circuit breaker [Q1] Grid cable/busbar terminals [L1, L2, L3] Cooling fans of the main breaker cubicle [M16, M17, M18] Capacitors of the LCL filter [C1, C2]...
- Page 34 34 Operation principle and hardware description Back view...
- Page 35 Cooling fan of the auxiliary control cubicle [M29] Upper cooling fans of the LCL filter cubicle [M33, M34] Smoke detector (customer variant, [A3]) Grid-side converter modules [T1]. Note: ACS880-87LC-4000A/4021A-7 contains five grid-side converter modules. Grid-side converter DC fuses [F5] Grid-side converter AC fuses [F1]...
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Page 36: Overview Of Power And Control Connections
36 Operation principle and hardware description Overview of power and control connections The diagram shows the power connections and internal control interfaces of the wind turbine converter. See also section Circuit boards (page 37). The option module slots on the control unit are reserved for internal use and communication. Slots 1…3 Slots 1…3 RDCO (slot 4) -
Page 37: Circuit Boards
Operation principle and hardware description 37 Circuit boards This example diagram shows the interconnections between the control boards of the converter. 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. Generator-side converter module Grid-side converter module... -
Page 38: Bamu Board
38 Operation principle and hardware description For information on the BCU control units, see chapter Control units 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: Type Designation Labels
The type designation label includes ratings, valid markings, type code and serial number of the converter. Each converter module is also individually labeled. Typical labels are shown below. ACS880-87LC-4000A/4132A-7+C143+D150+F276 +H372+H373+K457+K464+L502+L520+P902+P911 FRAME 4×R9iLC +6×R9iLC ABB Oy Hiomotie 13 00381 Helsinki Finland FRAME R9iLC Liquid cooling IP00... -
Page 40: Type Designation Key
The option codes follow the basic code. Each option code starts with an identifying letter (common for the whole product series), followed by descriptive digits. The option codes are separated by plus signs. The selections are listed below. For more information, contact your local ABB representative. -
Page 41: Basic Code
Operation principle and hardware description 41 Basic code Digit no. Name/Description Alternatives Description 1…6 Product series ACS880 ACS880 product series 8…11 Construction 87LC Cabinet mounted liquid-cooled wind turbine converter 13…23 Size See section Ratings Generator-side converter current rating / on page 107. - Page 42 42 Operation principle and hardware description Code Description Cabinet options G335 Current transformers for grid current measurement G396 Auxiliary 3-phase power output - 125 A (included as standard) G397 Auxiliary 3-phase power output - 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)
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Page 43: Mechanical Installation
Mechanical installation 43 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: Checklist Before Mechanical Installation
• Pozidriv and Torx (2.5 … 6 mm, 0.98 … 0.2 in) screwdrivers for the tightening of the frame screws (Screws needed for fastening the cabling boxes and other accessories delivered by ABB are included in the delivery. They are inside the cabinet. The delivery does not contain screws or tools to install the cabinet to the floor.) -
Page 45: Moving The Converter Package
Mechanical installation 45 Moving the converter package Moving the converter package by fork-lift WARNING! 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. -
Page 46: Lifting The Converter Package
46 Mechanical installation Lifting the converter package Max 60 Moving the converter on rollers Do not move the converter on rollers. Unpacking Unpack the wind turbine converter when you have moved the converter to its final installation location, or near it. 1. -
Page 47: Lifting The Converter - Abb Lift Adapter Bars (Customer Variant) Are In Use
The ordering 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. -
Page 48: Lifting The Converter
48 Mechanical installation Lifting the converter Obey these instructions when there are no ABB lift adapter bars in use: 1. Attach the lifting slings to holes of the lifting bars (a). Use long enough slings. See the minimum lifting angle in the figure below. -
Page 49: Placing The Converter
Mechanical installation 49 Placing the converter The cabinet can be placed into its final position with an iron bar and a wooden piece at the bottom edge of the cabinet. Place the wooden piece carefully to avoid damage to the cabinet frame. -
Page 50: Fastening The Cabinet To The Floor
50 Mechanical installation Fastening the cabinet to the floor Bolt the converter 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). -
Page 51: Lifting The Door
Mechanical installation 51 Lifting the door 1. Open the handles. 2. Detach the upper part of the door. 3. Lift the door upwards. Miscellaneous Cable duct in the floor below the cabinet You can construct cable ducts below the cabinet. The duct width must not exceed 450 mm (18 in). - Page 52 52 Mechanical installation...
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Page 53: Planning The Electrical Installation
Note: The installation must always be designed and made according to applicable local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the converter may experience problems that the warranty does not cover. -
Page 54: Checking The Compatibility Of The Generator And The Converter
You can avoid the stress on generator insulation by using ABB du/dt filters. du/dt filters also reduce bearing currents. The converter is equipped with the following output filters: •... -
Page 55: Selecting The Power Cables
Planning the electrical installation 55 To avoid damage to generator bearings, the cables must be selected and installed according to the instructions given in this manual. In addition, insulated N-end (non- converter end) bearings must be used. Selecting the power cables General rules ... - Page 56 56 Planning the electrical installation This table shows the minimum cross-sectional area related to the phase conductor size according to IEC 61800-5-1 when the phase conductor and the protective conductor are made of the same metal. If this is not so, the cross-sectional area of the protective earthing conductor shall be determined in a manner which produces a conductance equivalent to that which results from the application of this table.
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Page 57: Typical Power Cable Sizes
Planning the electrical installation 57 Typical power cable sizes CE cables Generator cables Converter type Cable Conductor Total quantity of parallel cables type type ACS880-87LC- 240 mm 185 mm 120 mm 95 mm 4000A/4021A-7 Copper 4000A/4132A-7 Copper Grid cables Converter type Cable Conductor... -
Page 58: Not Allowed Power Cable Types
58 Planning the electrical installation Not allowed power cable types 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 well-shielded (Al/Cu shield) four-conductor system (three phase conductors and a PE conductor or four conductors) Symmetrical shielded cable with individual shields for each phase conductor is not allowed on any cable size for grid and generator cabling. -
Page 59: Single Core Vs Multicore Cables In Grid Cabling
Planning the electrical installation 59 Single core vs multicore cables in grid cabling Use symmetrical grid cabling. Asymmetry leads to unequal current distribution between the conductors which may cause disturbances and fault trips. To avoid asymmetry, use symmetrical multicore (three-phase) cables where possible. Single core cabling is also allowed if the cables are grouped symmetrically. -
Page 60: Selecting The Dc Resistors
60 Planning the electrical installation Selecting the DC resistors For further information, contact your local ABB representative. Selecting the control cables General rules All control cables must be shielded. As a general rule, the control signal cable shield should be grounded directly in the wind turbine converter. -
Page 61: Routing The Cables
Planning the electrical installation 61 Routing the cables Route the generator cable away from other cable routes. It is recommended that the generator cable, grid cable and control cables are installed on separate trays. Avoid long parallel runs of generator cables with other cables in order to decrease electromagnetic interference caused by the rapid changes in the converter output voltage. -
Page 62: Protecting The Converter Installation
62 Planning the electrical installation Protecting the converter installation Protecting the grid cable in short-circuit situations Equip the cable with fuses. Size the fuses according to local safety regulations, appropriate voltage and the rated current of the converter. Protecting the generator and generator cable in short-circuit ... -
Page 63: Implementing The Emergency Stop Function
Planning the electrical installation 63 Implementing the emergency stop function The converter can be equipped with an emergency stop circuit which can be used to implement the emergency stop function. Converters with the option +Q951, see Emergency stop, stop category 0 (option +Q951) for ACS880-77LC/87LC wind turbine converters user's manual (3AXD50000040787 [English]). -
Page 64: Using A Safety Switch Between The Converter And Generator
64 Planning the electrical installation Using a safety switch between the converter and generator To minimize the emission level when safety switches are installed in the generator cable between the converter and the generator: • Install the equipment in a metal enclosure in a way that the conduit or generator cable shielding runs consistently without breaks from the converter to the generator. - Page 65 Planning the electrical installation 65 Install the protective component as close to the inductive load as possible. Do not install the protective components at the terminal block. 230 V AC 230 V AC + 24 V DC 1) Relay outputs; 2) Varistor; 3) RC filter; 4) diode...
- Page 66 66 Planning the electrical installation...
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Page 67: Electrical Installation
Electrical installation 67 Electrical installation Contents of this chapter This chapter describes the electrical installation procedure of the wind turbine converter. WARNING! Only qualified electricians are allowed to carry out the work described in this chapter. Read the complete safety instructions of the converter. If you ignore them, injury or death, or damage to the equipment can occur. -
Page 68: Grid Cable
1000 V DC. The insulation resistance of an ABB generator must exceed 100 Mohm (reference value at 25 °C or 77 °F). For the insulation resistance of other generators, please consult the manufacturer’s instructions. -
Page 69: Connection Procedure
Electrical installation 69 Connection procedure WARNING! See and obey the safety instructions of the converter. If you ignore them, injury or death, or damage to the equipment can occur. WARNING! Apply grease to stripped aluminum conductors before attaching them to non-coated aluminum cable lugs. -
Page 70: Connecting The Generator Cables
70 Electrical installation Connecting the generator cables Connection diagram Connection procedure WARNING! See and obey the safety instructions of the converter. If you ignore them, injury or death, or damage to the equipment can occur. WARNING! Apply grease to stripped aluminum conductors before attaching them to non-coated aluminum cable lugs. - Page 71 Electrical installation 71 When single-core cables without metal shield are used: • Lead the cables into the inside of the cubicle through the IP sealing glands. • Connect the phase conductors to terminals U2, V2 and W2, and the PE conductors to the PE terminal.
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Page 72: Connecting The External Power Supply Cable For The Auxiliary Circuit
72 Electrical installation Connecting the external 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: Connecting The Control Cables
Electrical installation 73 Connecting 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...
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Page 76: Default I/O Connection Diagrams
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: Installation Checklist
Installation checklist 77 Installation checklist Contents of this chapter This chapter contains instructions for checking the installation of the wind turbine converter. Before you start Check the mechanical and electrical installation of 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. -
Page 78: Checklist
78 Installation checklist Checklist Make sure that … The ambient operating conditions meet the specifications given in chapter Technical data. The converter has been fixed properly on an even, horizontal and non-flammable floor and if necessary due to vibration etc, also from top to the wall or roof. The cooling circuit joints are tight. -
Page 79: Maintenance
Maintenance 79 Maintenance Contents of this chapter This chapter contains preventive maintenance intervals and instructions. -
Page 80: Maintenance Intervals
80 Maintenance Maintenance intervals The table below shows the maintenance tasks which can be done by the end user. For more information, contact your local ABB Service representative (www.abb.com/searchchannels). Maintenance task/object Years from start-up 11 12 … Replacement Cooling fans... -
Page 81: Maintenance Timers And Counters
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. -
Page 82: Cabinet
82 Maintenance Cabinet Replacing inlet (door) filter (IP54, customer variant) 1. Remove all the fasteners (8 pcs) from the upper support plate (a) and the fasteners (4 pcs) attaching the lower support plate (b) to the door plate. 2. Remove the upper support plate (a). 3. -
Page 83: Power Connections
For resetting the running time after a fan replacement, contact ABB. Replacement fans are available from ABB. Do not use other than ABB specified spare parts. -
Page 84: Replacing The Cooling Fan Of The Converter Module
84 Maintenance Replacing the cooling fan of the converter module WARNING! Only qualified electricians are allowed to do this work. Read the complete safety instructions of the converter. If you ignore the instructions, physical injury, death, or damage to the equipment can occur. 1. - Page 85 Maintenance 85 Air flow direction...
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Page 86: Replacing The Fan Of The Main Breaker Cubicle
86 Maintenance Replacing the fan of the main breaker cubicle WARNING! Only qualified electricians are allowed to do this work. Read the complete safety instructions of the converter. If you ignore the instructions, physical injury, death, or damage to the equipment can occur. 1. - Page 87 Maintenance 87...
- Page 88 88 Maintenance Arrow indicating the air flow direction...
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Page 89: Replacing The Cooling Fan Of The Auxiliary Control Cubicle
Maintenance 89 Replacing the cooling fan of the auxiliary control cubicle WARNING! Only qualified electricians are allowed to do this work. Read the complete safety instructions of the converter. If you ignore the instructions, physical injury, death, or damage to the equipment can occur. 1. - Page 90 90 Maintenance Air flow circulation...
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Page 91: Replacing The Upper Cooling Fan Of The Lcl Filter Cubicle
Maintenance 91 Replacing the upper cooling fan of the LCL filter cubicle WARNING! Only qualified electricians are allowed to do this work. Read the complete safety instructions of the converter. If you ignore the instructions, physical injury, death, or damage to the equipment can occur. 1. - Page 92 92 Maintenance Air flow direction, side view of the cubicle Upper cooling fans Door of the LCL filter cubicle...
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Page 93: Replacing The Lower Cooling Fan Of The Lcl Filter Cubicle
Maintenance 93 Replacing the lower cooling fan of the LCL filter cubicle WARNING! Only qualified electricians are allowed to do this work. Read the complete safety instructions of the converter. If you ignore the instructions, physical injury, death, or damage to the equipment can occur. 1. - Page 94 94 Maintenance 5. Remove the fastening screws of the fan (M4 × 60 mm, 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.
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Page 95: Fuses
Maintenance 95 Fuses Replacing the DC fuses WARNING! Only qualified electricians are allowed to do this work. Read the complete safety instructions of the converter. If you ignore the instructions, physical injury, death, or damage to the equipment can occur. 1. -
Page 96: Replacing The Ac Fuses
96 Maintenance Replacing the AC fuses WARNING! Only qualified electricians are allowed to do this work. Read the complete safety instructions of the converter. If you ignore the instructions, physical injury, death, or damage to the equipment can occur. 1. -
Page 97: Converter Module
Maintenance 97 Converter module Replacing the converter module WARNING! Only qualified electricians are allowed to do this work. Read the complete safety instructions of the converter. If you ignore the instructions, physical injury, death, or damage to the equipment can occur. WARNING! If you ignore the following instructions, physical injury, death, or damage to the equipment can occur: •... - Page 98 98 Maintenance 3. Remove the shrouds on top and bottom of module 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.
- Page 99 Maintenance 99 8. Open top liquid connection nut with 30 mm wrench. Pull the pipe upwards to release it. 9. Open two module support bolts from top. 10. Open bottom liquid connection with 30 mm wrench. Pull the pipe downwards to release it.
- 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.
- 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).
- Page 102 102 Maintenance 16. Insert M8 bolt to the hole on the top part of the module and turn it clockwise. This will help in pushing the module out. It also helps in pulling simultaneously from the handle while turning the screw. 17.
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Page 103: Capacitors
Capacitor failure is usually followed by the converter module and module fuse failure, or a fault trip. Contact ABB if capacitor failure is suspected. Replacements are available from ABB. Do not use other than ABB specified spare parts. -
Page 104: Bcu Control Unit
104 Maintenance BCU control unit WARNING! Only qualified electricians are allowed to do this work. Do not remove or insert a memory unit when the converter is powered or the control unit is powered from an external power source. Read the complete safety instructions of the converter. If you ignore the instructions, physical injury, death, or damage to the equipment can occur. -
Page 105: Replacement Illustration
Maintenance 105 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). - Page 106 106 Maintenance...
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Page 107: Technical Data
Technical data 107 Technical data Contents of this chapter This chapter contains the technical data of the ACS880-87LC-4000A/4021A-7 and ACS880-87LC-4000A/4132A-7. Ratings Converter type Generator-side converter Grid-side converter ratings Cos phi ratings ACS880-87LC- grid = 690 V 4000A/4021A-7 4302 4000 4325... -
Page 108: Definitions
100 m (328 ft). Derating is allowed only on maximum continuous current for grid and generator. If the installation site is situated higher than 2000 m (6562 ft) above sea level, contact ABB. Alternatively the derating can be handled with cooling liquid temperature derating. 1 °C for every 100 m. -
Page 109: Fuses
Technical data 109 Fuses Main circuit AC fuses Converter type AC fuses ACS880-87LC- Type A rms = 690 V 4000A/4021A-7 Bussmann 170M6116 1250 4000A/4132A-7 Bussmann 170M6116 1250 3AXD10000011539 Main circuit DC fuses Converter type DC fuses ACS880-87LC- Type A rms = 690 V 4000A/4021A-7... -
Page 110: Losses, Cooling Data And Noise
110 Technical data Losses, cooling data and noise Converter type Losses Cooling data Noise ACS880-87LC- Liquid Coolant Mass flow Pressure loss quantity (tolerance -2%… +20%) l/min = 690 V 4000A/4021A-7 < 70 4000A/4132A-7 < 70 3AXD10000011539 Internal cooling circuit data ... -
Page 111: Terminal And Lead-Through Data For The Generator Cable
Power factor -1…0…1 Harmonic distortion Total harmonic current distortion (n = 2...40) < 5%. Total harmonic voltage distortion (n = 2...40) < 5%, when R > 7. Requirements for the grid connection For applicable grid codes, contact your local ABB representative. -
Page 112: Generator Connection Data
Condensation and/or formation of ice inside the converter cabinet is not allowed in any operational circumstances. ABB additional extension to ambient surrounding temperature, outside the cabinet, -30 °C … 55 °C (-22 °F … 131 °F). See also section Temperature derating on page 108. -
Page 113: Ambient Conditions
ABB converter warranty is terminated. If the customer is unsure about the environmental conditions and/or corrosion class inside the wind turbine, the customer is responsible for contacting ABB before the converter installation, and get an approval from ABB to use the converter in such an environmental condition and/or corrosive class. -
Page 114: Materials
IEC 62635 guidelines. To aid recycling, plastic parts are marked with an appropriate identification code. Please contact your local ABB distributor for further information on environmental aspects and recycling instructions for professional recyclers. End of life treatment must follow international and local regulations. -
Page 115: Applicable Standards
Technical data 115 Applicable standards The converter 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 + Safety of machinery. Electrical equipment of machines. Part 1: General A1:2009 + AC:2010 requirements. -
Page 116: Regulatory Compliance Mark (Rcm)
116 Technical data Regulatory Compliance Mark (RCM) RCM marking is pending. Applies as Compliance with EN 61800-3:2004. EAC marking The converter has EAC certification. EAC marking is required in Russia, Belarus and Kazakhstan. Compliance with EN 61800-3:2004/A1:2012 Definitions EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to operate without problems within an electromagnetic environment. -
Page 117: Category C4
Equipment 2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available from the local ABB representative. 3. The generator and control cables are selected as specified in the hardware manual. 4. The converter is installed according to the instructions given in the hardware manual. -
Page 118: Weee Marking
ABB and its affiliates are not liable for damages and/or losses related to such security breaches, any... -
Page 119: Control Units Of The Converter
Control units of the converter 119 Control units of the converter Contents of this chapter This chapter describes the layout and connections of the control units and contains the specifications of the inputs and outputs of the control units. For the actual connections of the control units used in the ACS880-87LC converter, see the circuit diagrams delivered with the converter. -
Page 120: Layout And Connections
120 Control units of the converter Layout and connections BCU layout and connections Description I/O terminals (see the following diagram) SLOT 1 I/O extension, encoder interface or fieldbus adapter module connection. (This is the sole location for an FDPI-02 diagnostics and panel interface.) SLOT 2 I/O extension, encoder interface or... - Page 121 Control units of the converter 121 Description Analog inputs Analog outputs Digital inputs, Digital input interlock (DIIL) XRO3 XDIO Digital input/outputs XD24 XPOW XD2D Drive-to-drive link XD24 +24 V output (for digital inputs) XRO2 XETH Ethernet port XDIO XPOW External power input XRO1 Relay output RO1 XRO1...
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Page 122: Control Unit Connector Data
122 Control units of the converter Control unit connector data Power supply Connector pitch 5 mm, wire size 2.5 mm (XPOW) 24 V (±10%) DC, 2 A External power input. Two supplies can be connected to BCU for redundancy. Relay outputs RO1…RO3 Connector pitch 5 mm, wire size 2.5 mm (XRO1…XRO3) 250 V AC / 30 V DC, 2 A... - Page 123 Control units of the converter 123 Analog outputs AO1 and AO2 Connector pitch 5 mm, wire size 2.5 mm (XAO) 0…20 mA, R < 500 ohm load Frequency range: 0…500 Hz Resolution: 11 bit + sign bit Inaccuracy: 2% of full scale range Drive-to-drive link Connector pitch 5 mm, wire size 2.5 mm (XD2D)
- Page 124 124 Control units of the converter...
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Page 125: Dimension Drawings
Dimension drawings 125 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...
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Page 129: Cooling And Heating
Cooling and heating 129 Cooling and heating Contents of this chapter This chapter deals with the internal cooling circuit. Hardware description General The internal cooling circuit covers the heat-generating electrical components and transfers the heat to the external cooling circuit that is usually part of a larger external cooling system. - Page 130 130 Cooling and heating Coolant OUT Generator-side Generator- Grid-side converter Grid-side converter converter modules side modules modules converter modules Choke 1 Choke 2 Coolant IN...
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Page 131: Planning The Cooling System
Install a bleeding valve at the highest point of the cooling circuit. Bleeding valve is not included in the ABB converter delivery as standard. It can be ordered as an option (+G422). The materials used in the cooling system are listed in Specifications on page 136. -
Page 132: Mechanical Installation
132 Cooling and heating Mechanical installation Connecting the internal cooling circuit to a customer cooling unit The converter delivery does not include the liquid cooling unit that is to be connected to the converter cabinet. Connecting the liquid pipes Note: It is recommended to use closing valves in the pipe connections of the cooling circuit. -
Page 133: Filling Up And Bleeding The Internal Cooling Circuit
The most practical location for the valve 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). -
Page 134: Draining The Internal Cooling Circuit
134 Cooling and heating 13. Repeat steps 10…12 a few times until all air is let out of the cooling circuit. Listen for a humming sound and/or feel the piping for vibration to find out if there is still air left in the circuit. - Page 135 Cooling and heating 135 b. Humidity control - set cooling liquid temperature at least +10 °C (+50 °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.
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Page 136: Specifications
42.2 37.1 Not allowed as standard but the coolant temperature must be 5 °C (41 °F) or above. Consult an ABB representative if operation below coolant temperature 5 °C (41 °F) is required. Example: At an air temperature of 45 °C (113 °F) and relative humidity of 65% the coolant temperature may not be below +36.8 °C (98.2 °F). -
Page 137: Water Quality
WARRANTY DOES NOT COVER DAMAGE OCCURRING FROM USE OF IMPROPER COOLANT. Coolant concentration ABB recommends diluting coolant 50:50 with water. Note that the concentration of coolant should not be less than 33% and not more than 60%. Following table shows how the diluting portion effects to frost protection. -
Page 138: Approved Coolants
• BASF Glysantin G30® or Valvoline Zerex G30. For other coolants, contact your local ABB representative. WARNING! Do not mix different approved coolants in any conditions! Replace the cooling liquid always with same cooling liquid! Mixing different coolant types is a risk for cooling system corrosion. -
Page 139: Heating
Cooling and heating 139 Heating The converter is not equipped with a heating element. Thus, it must be heated using the coolant circuit. The external liquid cooling unit must be equipped with a heater capable of heating the converter up within reasonable time. Temperatures in each converter cubicle are monitored separately by using thermostats with a fixed set point of 10 ±... - Page 140 140 Cooling and heating Note: If the converter temperature goes again below 10 °C inside any converter cubicle, the converter restarts the heating procedure again and the normal start can continue only after the temperature is on sufficient level. See section Cold start (-30 °C …...
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Page 141: Circuit Diagram
Cooling and heating 141 Circuit diagram The 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...
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Page 143: Further Information
Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to abb.com/searchchannels. - Page 144 © Copyright 2018 ABB. All rights reserved. Specifications subject to change without notice.