ABB ACS880-77CC Hardware Manual
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ABB ACS880-77CC Hardware Manual

ABB ACS880-77CC Hardware Manual

Wind turbine converters
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ABB WIND TURBINE CONVERTERS
ACS880-77CC wind turbine converters
Hardware manual

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Summary of Contents for ABB ACS880-77CC

  • Page 1 — ABB WIND TURBINE CONVERTERS ACS880-77CC wind turbine converters Hardware manual...
  • Page 3 ACS880-77CC wind turbine converters Hardware manual Table of contents 1. Safety instructions 4. Mechanical installation 6. Electrical installation 3AXD50000813605 Rev A Original instructions EFFECTIVE: 2021-12-22...

  • Page 5: Table Of Contents

    Table of contents 5 Table of contents 1 Safety instructions Contents of this chapter ................Use of warnings and notes ............... General safety in installation, start-up and maintenance ........Electrical safety in installation, start-up and maintenance ........Precautions before electrical work ............Additional instructions and notes .............
  • Page 6 6 Table of contents Unpacking ................... Lifting the converter ................Placing the converter ................Fastening the cabinet to the floor ..............Internal cooling circuit ................Lifting the door ..................Miscellaneous ..................Cable duct in the floor below the cabinet ........... Electric welding .................
  • Page 7 Table of contents 7 Generator stator and generator cable ............Connecting the grid cables ............... Connection diagram ................Connection procedure ................. Connecting the generator cables ..............Connection diagram ................Connection procedure ................. Connecting the control cables ..............Default I/O connection diagrams ............. 7 Installation checklist Contents of this chapter ................
  • Page 8 8 Table of contents Fuses ....................Main circuit AC fuses ................Main circuit DC fuses ................Fuses for the voltage measurement board BAMU ........Fuses of the DC chopper ..............Dimensions, weights and free space requirements ........... Losses, cooling data and noise ..............Internal cooling circuit data ..............
  • Page 9 Table of contents 9 Connector data ..................12 Dimension drawings Contents of this chapter ................13 Cooling and heating Contents of this chapter ................Hardware description ................General ..................Diagram of the internal cooling and heating circuit ........Planning the cooling system ..............Connection to a cooling unit ..............

  • 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.
  • Page 13 Safety instructions 13 WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. • Use safety shoes with a metal toe cap. Use protective gloves. • Use protective eyewear when working with the liquid cooling system. •...

  • Page 14: Electrical Safety In Installation, Start-Up And Maintenance

    14 Safety instructions 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. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 15: Additional Instructions And Notes

    Safety instructions 15 Install temporary grounding as required by the local regulations. Ask the person in control of the electrical installation work for a permit to work. Additional instructions and notes ￭ WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur.

  • 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: Disconnecting The Charging Circuit From The Main Circuit

    18 Safety instructions Disconnecting the charging circuit from the main circuit ￭ WARNING! If you are not a qualified electrician, do not proceed. Make sure that you have opened the main circuit breaker (Q1). See section Opening and disconnecting the main circuit breaker (page 16).

  • Page 19: Disconnecting The Auxiliary Power Supply (If Present)

    Safety instructions 19 Disconnecting the auxiliary power supply (if present) ￭ WARNING! If you are not a qualified electrician, do not proceed. Make sure that you have opened the main circuit breaker (Q1). See section Opening and disconnecting the main circuit breaker (page 16).

  • Page 20: Grounding

    20 Safety instructions 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 21: Work On The Liquid Cooling System

    Safety instructions 21 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: Quick Installation, Commissioning And Operation Flowchart

    24 Introduction to the manual Quick installation, commissioning and operation flowchart Task Plan the installation. Check: ambient conditions, ratings, Technical data (page 87) required external cooling circuit arrangements, compat- Planning the electrical installation (page 49) ibility of the generator, power cable connection, etc. Option manuals (if optional equipment is included) Select the cables.

  • Page 25: Terms And Abbreviations

    Introduction to the manual 25 Terms and abbreviations Term Description Auxiliary control unit. Contains control electronics, auxiliary voltage circuitry, etc. BAMU Auxiliary measurement unit BCON Type of control board Type of control unit Control unit The part in which the control program runs. Converter Converts direct current and voltage to alternating current and voltage, or vice versa.

  • Page 26: Related Documents

    26 Introduction to the manual Related documents Name Code General manuals Drive/converter/inverter safety instructions 3AXD50000037978 ACS880-77CC wind turbine converters hardware manual 3AXD50000813605 ACS880-77LC/-87LC/-87CC wind turbine converters system description 3AXD50000022022 Emergency stop, stop category 0 (option +Q951) for ACS880-77LC/-87LC/-87CC wind 3AXD50000040787 turbine converters user's manual Drive composer start-up and maintenance PC tool user’s manual...

  • Page 27: Operation Principle And Hardware Description

    This chapter describes the operation principle and the construction of the wind turbine converter. Operation principle The ACS880-77CC is a four-quadrant, cabinet-mounted combined-cooled converter intended for full power conversion 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.

  • Page 28: Generator Control

    28 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 29: Overview Diagram Of The Wind Turbine Converter

    Operation principle and hardware description 29 Overview diagram of the wind turbine converter An example single-line diagram of the wind turbine converter is shown below.

  • Page 30: Layout Drawing

    30 Operation principle and hardware description Layout drawing Layout of the wind turbine converter is shown below. Description Generator-side converter cubicle Grid-side converter cubicle LCL filter cubicle Main breaker cubicle Auxiliary control cubicle Generator cable lead-throughs Generator cable terminals [U2, V2, W2] Output contactors (optional) Generator-side converter modules Generator-side converter DC fuses...
  • Page 31 Operation principle and hardware description 31 Description Cooling fan of the auxiliary control cubicle Optional heater for cold environment Coolant connection of the cooling unit (inlet pipe) Coolant connection of the cooling unit (outlet pipe)

  • Page 32: Overview Of Power And Control Connections

    32 Operation principle and hardware description Overview of power and control connections The diagrams show the power connections and internal control interfaces of the wind turbine converter. See also section Circuit boards (page 34). The option module slots on the control unit are reserved for internal use and communication.

  • Page 33: Slave

    Operation principle and hardware description 33 Slave ￭ S500 S500 CI581-CN AX522 XCAN BCON Description Slots 1…3 RDCO (slot 4) BCU-x5 control unit External control via Ethernet Grid-side converter Generator-side converter...

  • Page 34: Circuit Boards

    34 Operation principle and hardware description Circuit boards These example diagrams show the interconnections between the circuit boards of the converter. For further details, see the delivery-specific circuit diagrams. For information on the BCU control units, see chapters BCU-x2 control unit BCU-x5 control unit.
  • Page 35 Operation principle and hardware description 35...

  • Page 36: Bamu Board

    36 Operation principle and hardware description 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 37: Type Designation Key

    Ratings of the converter Number and frame size of the converter modules. In the upper label for the ACS880-77CC converter, there are four generator-side converter modules, four grid-side converter modules, and the frame size is R9iLC. In the lower label for converter module, the frame size of the module is R9iLC.

  • Page 38: Basic Code

    38 Operation principle and hardware description Basic code ￭ Digit no. Name/Description Alternatives Description 1…6 Product series ACS880 ACS880 product series 8…11 Construction 77CC Cabinet-installed combined-cooled wind turbine converter 13…23 Size See the ratings. Generator-side converter current rating / Grid-side converter current rating Voltage rating 7 –...
  • Page 39 Operation principle and hardware description 39 Code Description I/O options L500 FIO-11 analog I/O extension module L501 FIO-01 digital I/O extension module L502 FEN-31 HTL incremental encoder interface module L503 DDCS communication 3 L504 Additional I/O - terminal block L505 Thermistor relay L506 Pt100 relay...

  • Page 41: Mechanical Installation

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

  • Page 42: 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 43: Moving The Converter Package

    Mechanical installation 43 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 44: Moving The Converter On Rollers

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

  • Page 45: Unpacking

    Detach the converter from its platform, lift the converter and remove the platform. Lifting the converter Obey these instructions when there are no ABB lift adapter bars in use: 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 46: Placing The Converter

    46 Mechanical installation 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 47: Fastening The Cabinet To The Floor

    Mechanical installation 47 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 (page 47)).
  • Page 48 48 Mechanical installation • Weld only the flat bar under the cabinet, never the cabinet frame itself. • Clamp the welding electrode onto the flat bar about to be welded or to the next flat bar of the cabinet (within 0.5 meters (1’6”) of the welding point). WARNING! If the welding return wire is connected improperly, the welding circuit may damage electronic circuits in the cabinet.

  • Page 49: Planning The Electrical Installation

    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 50: Checking The Compatibility Of The Generator And The Converter

    ABB power modules are equipped with internal du/dt filters which reduce the bearing currents and stress on the generator insulations. In addition, a common mode filter can be used to reduce such stresses on the generator-side.

  • Page 51: Selecting The Power Cables

    Planning the electrical installation 51 • du/dt filter protects generator insulation system and reduces bearing currents • common mode filter mainly reduces bearing currents (option). 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.

  • Page 52: Typical Power Cable Sizes

    Typical power cable sizes ￭ CE cables Generator cables Converter type Cable type Conductor type Total quantity of parallel conductors per phase ACS880-77CC- 300 mm 240 mm 185 mm 6880A/5500A-7 Copper 2×6 2×9 2×10...

  • Page 53: Alternative Power Cable Types

    Planning the electrical installation 53 DC resistor cables Converter type Cable type Conductor Number of conductor pairs per DC chopper module type ACS880-77CC- 70 kcmil 6880A/5500A-7 Copper 2×1 Alternative power cable types ￭ The power cable types that you can use with the converter are shown below.

  • Page 54: Generator Cable Shield

    54 Planning the electrical installation Generator cable shield If the generator cable shield is used as the sole protective earth conductor of the generator, make sure that the conductivity of the shield is sufficient. See subsection General rules above, or IEC 61800-5-1. To effectively suppress radiated and conducted radio-frequency emissions, the cable shield conductivity must be at least 1/10 of the phase conductor conductivity.

  • Page 55: Conduit

    Planning the electrical installation 55 Conduit Bridge the joints of the conduits with a 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.

  • Page 56: Relay Cable

    ￭ The cable type with braided metallic screen (for example, ÖLFLEX from Lapp Kabel, Germany) has been tested and approved by ABB. 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.

  • Page 57: Control Cable Ducts

    Planning the electrical installation 57 Control cable ducts ￭ 230 V AC 24 V DC (120 V AC) 230 V AC 24 V DC (120 V AC) Picture on the left: Lead 24 V and 230/120 V control cables in separate ducts into the inside of the cabinet.

  • Page 58: Protecting The Converter Against Ground Faults In The Converter Or Grid Cable

    (This is not a personal safety or a fire protection feature.) You can disable both ground fault protective functions (not recommended); refer to the firmware manual. Implementing the emergency stop function For further information, contact your local ABB representative. Implementing the grid fault ride-through function See the firmware manual.
  • Page 59 Planning the electrical installation 59 230 V AC 230 V AC + 24 V DC Relay outputs Varistor RC filter Diode...

  • Page 61: Electrical Installation

    Electrical installation 61 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 62: Generator Stator And Generator Cable

    Measure the insulation resistance between each phase conductor and the protective ground conductor using a measuring voltage of 1000 V DC. The insulation resistance of an ABB generator must exceed 100 Mohm (reference value at 25 °C (77 °F)). For the insulation resistance of other generators, please consult the manufacturer’s instructions.

  • Page 63: Connection Procedure

    Electrical installation 63 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 64: Connecting The Generator Cables

    64 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 65 Electrical installation 65 • 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. Tighten the phase and PE conductors. For the tightening torques, see the technical data.

  • Page 66: Connecting The Control Cables

    66 Electrical installation Connecting the control cables Control cable terminals for customer connections are located in the auxiliary control cubicle. For wiring, see the circuit diagrams delivered with the converter. Control cable terminals for customer connections and lead-throughs in the auxiliary control cubicle Connector Description Customer connection for 400 V AC non-UPS auxiliary power supply...

  • Page 67: Installation Checklist

    Installation checklist 67 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 68: Checklist

    68 Installation checklist Checklist Make sure that … The ambient operating conditions meet the specifications given in the 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 69: Maintenance

    Maintenance Contents of this chapter This chapter contains preventive maintenance intervals and instructions. Maintenance intervals The table below shows the maintenance tasks which can be done by the end user. For more information, consult your local ABB Service representative (https://new.abb.com/power-converters-inverters/wind-turbines/service).
  • Page 70 Performance of on/off-site work (commissioning, tests, measurements or other work) 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.

  • Page 71: Maintenance Timers And Counters

    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 10000 operations. For more information, refer to the maintenance manual of the ABB SACE breaker. Maintenance timers and counters The control program has maintenance timers and counters that can be configured to generate a warning when a pre-defined limit is reached.

  • Page 72: Cleaning The Outlet (Door Or Roof) Filters

    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. All the fans in the converter are of the same type.
  • Page 73 Maintenance 73 Air flow direction is towards the converter module.

  • Page 74: Replacing The Fan Of The Main Breaker Cubicle

    74 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. Disconnect the converter from the all power sources and make sure it is safe to start the work.

  • Page 75: Replacing The Cooling Fan Of The Auxiliary Control Cubicle

    Maintenance 75 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. Disconnect the converter from the all power sources and make sure it is safe to start the work.

  • Page 76: Replacing The Cooling Fan Of The Lcl Filter Cubicle

    76 Maintenance Replacing the 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. Disconnect the converter from the all power sources and make sure it is safe to start the work.

  • Page 77: Fuses

    Maintenance 77 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. Disconnect the converter from the all power sources and make sure it is safe to start the work.

  • Page 78: Replacing The Ac Fuses

    78 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. Disconnect the converter from the all power sources and make sure it is safe to start the work.

  • Page 79: Converter Module

    Maintenance 79 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 80 80 Maintenance Remove the pipe clamps from top tubes. Open top liquid connection nut with 30 mm wrench. Pull the pipe upwards to release Open two module support bolts from top.
  • Page 81 Maintenance 81 10. Open bottom liquid connection with 30 mm wrench. Pull the pipe downwards to release 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. 13.
  • Page 82 82 Maintenance 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 83 Maintenance 83 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.
  • Page 84 84 Maintenance 17. Pull the module out a bit (5 cm [2 in]) and install the lifting hook to the lifting hole. 18. Pull the whole module onto the installation stand. Keep the pipes and wires away from the sharp edges and be careful not to damage the coolant connections. 19.

  • Page 85: 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 86: Replacement Illustration

    Insert the new card in reverse order. Tightening torque for fastening screw is 0.7 N·m (0.5 lbf·ft). Repeat the replacement procedure for other BCU control unit if needed. Replacement illustration ￭ Main circuit breaker For ABB-SACE main circuit breaker maintenance, refer to the manufacturer’s instructions (1SDH001000R0002).

  • Page 87: Technical Data

    Technical data 87 Technical data Contents of this chapter This chapter contains the technical data of the ACS880-77CC. Ratings Generator-side converter Grid-side converter ratings ratings Converter type Cos phi ACS880-77CC- grid = 690 V 6880A/5500A-7 6655 6400 5916 5500 6573...

  • Page 88: Derating

    1 °C (1.8 °F) for every 100 m (328 ft). Derating is allowed only on maximum continuous current for grid and generator. If the installation site is located higher than 2000 m (6562 ft) above sea level, contact your local ABB representative. Type equivalence table...

  • Page 89: Fuses

    Technical data 89 Fuses Main circuit AC fuses ￭ AC fuses Converter type Type ACS880-77CC- A rms = 690 V 6880A/5500A-7 170M6416 1250 2×12 3AXD10000011539 Main circuit DC fuses ￭ DC fuses Converter type Type ACS880-77CC- A rms = 690 V...

  • Page 90: Losses, Cooling Data And Noise

    Losses Cooling data Liquid Coolant Mass flow Pressure Noise Converter type quantity loss (tolerance ACS880-77CC- -2%… +20%) l/min = 690 V 6880A/5500A-7 2×29 2×270 <90 3AXD10000011539 1) Measured with 50 °C (122 °F) coolant. 2) Excluding hydrostatic pressure. Internal cooling circuit data ￭...

  • Page 91: Grid Specification

    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. Generator connection data Generator types AC induction generators, permanent magnet generators Voltage (U 0…110% U...

  • Page 92: Efficiency

    1) Condensation and/or formation of ice inside the converter cabinet is not allowed in any operational circumstances. 2) ABB additional extension to ambient surrounding temperature, outside the cabinet, -30 °C…55 °C (-22 °F…131 °F). See also the instructions for ambient temperature derating.

  • Page 93: Ambient Conditions

    Technical data 93 Ambient conditions Environmental limits for the converter are given below. The converter must be used in a heated, indoor controlled environment. Operation installed for Storage in protective Transportation in protect- stationary use package ive package Installation site altitude 0 …...

  • Page 94: Materials

    Painted or tin- or silver-plated copper or aluminum Internal cooling circuit pip- Aluminum, acid-fast stainless steel, PA pipes Air filters (door) IP42 filter (Air-Tex G-150): 5158 × 520 × 12 mm (ABB code: 64665324) Fire safety of materials Insulating materials and non-metallic items: Mostly self-extinctive (IEC 60332-1) Packaging Frame: Wood or plywood.

  • Page 95: Applicable Standards

    Technical data 95 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. Safety of machinery. Electrical equipment of machines. Part 1: General require- • EN 60204-1:2006 + ments.

  • Page 96: Regulatory Compliance Mark (Rcm)

    96 Technical data The drive is an electronic product which is covered by the European Low Voltage Directive. The drive is equipped with a main circuit breaker which can be used in safety functions for machinery. These safety functions are in the scope of the Machinery Directive as safety components, and appropriate harmonized standards (EN ISO 13849 or EN 62061) shall be applied.

  • Page 97: Etl Marking

    Equipment (victim) An EMC plan for preventing disturbances is drawn up for the installation. A template is available from the local ABB representative. The generator and control cables are selected as specified in the hardware manual. The converter is installed according to the instructions given in the hardware manual.
  • Page 98 Notwithstanding any other provision to the contrary and regardless whether the contract is terminated or not, ABB and its affiliates are under no circumstances liable for damages and/or losses related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or theft of data or information.

  • Page 99: Bcu-X2 Control Unit

    This chapter describes the layout and connections of the BCU-x2 control unit and contains the specifications of the inputs and outputs of the control unit. For the actual connections of the control units used in the ACS880-77CC converter, see the circuit diagrams delivered with the converter.

  • Page 100: Layout And Connections

    100 BCU-x2 control unit Layout and connections Description I/O terminals 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 fieldbus adapter module connection SLOT 3 I/O extension, encoder interface or fieldbus...
  • Page 101 BCU-x2 control unit 101 Description Analog inputs Analog outputs Digital inputs, Digital input interlock (DIIL) XRO3 XD24 XPOW XDIO Digital input/outputs XD2D Drive-to-drive link XRO2 XD24 +24 V output (for digital inputs) XDIO XETH Ethernet port XPOW External power input XRO1 XRO1 Relay output RO1...

  • Page 102: Connector Data

    102 BCU-x2 control unit Connector data Power supply (XPOW) Connector pitch 5 mm, wire size 2.5 mm 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 Protected by varistors...
  • Page 103 BCU-x2 control unit 103 Analog outputs AO1 and AO2 (XAO) Connector pitch 5 mm, wire size 2.5 mm 0…20 mA, R < 500 ohm load Frequency range: 0…500 Hz Resolution: 11 bit + sign bit Inaccuracy: 2% of full scale range XD2D connector Connector pitch 5 mm, wire size 2.5 mm Physical layer: RS-485...

  • Page 105: Bcu-X5 Control Unit

    This chapter describes the layout and connections of the BCU-x5 control unit and contains the specifications of the inputs and outputs of the control unit. For the actual connections of the control units used in the ACS880-77CC converter, see the circuit diagrams delivered with the converter.

  • Page 106: Layout And Connections

    106 BCU-x5 control unit Layout and connections Description I/O terminals 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 fieldbus adapter module connection SLOT 3 I/O extension, encoder interface or fieldbus...
  • Page 107 BCU-x5 control unit 107 Description Analog inputs Analog outputs Digital inputs, Digital input interlock (DIIL) XDIO Digital input/outputs XRO3 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...
  • Page 108 108 BCU-x5 control unit Description XCAN CAN bus connection XCAN...

  • Page 109: Connector Data

    BCU-x5 control unit 109 Connector data Power supply (XPOW) Connector pitch 5 mm, wire size 2.5 mm 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 Protected by varistors...
  • Page 110 110 BCU-x5 control unit Analog outputs AO1 and AO2 (XAO) Connector pitch 5 mm, wire size 2.5 mm 0…20 mA, R < 500 ohm load Frequency range: 0…500 Hz Resolution: 11 bit + sign bit Inaccuracy: 2% of full scale range XD2D connector Connector pitch 5 mm, wire size 2.5 mm Physical layer: RS-485...

  • Page 111: Dimension Drawings

    Dimension drawings 111 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 112 112 Dimension drawings...
  • Page 113 Dimension drawings 113...
  • Page 114 114 Dimension drawings...

  • Page 115: Cooling And Heating

    Cooling and heating 115 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. Diagram of the internal cooling and heating circuit ￭...
  • Page 116 116 Cooling and heating Choke 1 Choke 2 Generator-side converter modules Grid-side converter modules Coolant OUT Coolant IN...

  • Page 117: 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. The materials used in the cooling system are listed in section Specifications (page 121).

  • Page 118: Mechanical Installation

    118 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 119: Converters With A Customer Cooling Unit

    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.

  • Page 120: Draining The Internal Cooling Circuit

    120 Cooling and heating Draining the internal cooling circuit You can drain the internal cooling circuit through the cooling unit as follows: Note: Draining coolant into the sewer system is not allowed. WARNING! High-pressure hot coolant may be present in the internal cooling circuit. No work on the cooling circuit is allowed until the pressure is lowered down by stopping the pumps and draining coolant.

  • Page 121: Specifications

    ). If coolant inlet temperature cannot be higher, the temperature values in the table below are absolute minimums. To avoid all kind of condensation inside the converter: ABB highly recommends to maintain / heat up the cooling liquid +10 °C (+50 °F) above the ambient temperature (ie, air temperature outside the converter), within the limits that the cooling liquid minimum temperature is +5 °C (41 °F) and maximum temperature is +50 °C (122 °F).

  • Page 122: Pressure Limits

    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 flow.

  • Page 123: Coolant Concentration

    Cooling and heating 123 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 124: Converter Cold Start

    Manual dry-out ￭ Most of the ACS880 wind turbine converters by ABB require manual dry-out before operating them for the first time in commissioning, or after a longer standstill. Manual dry-out means that the converter/turbine operator must evaluate the need of converter dry-out based on the situation and the length of turbine standstill.

  • Page 125: Automatic Software-Controlled Dry-Out

    Automatic software-controlled dry-out ￭ Some of the latest versions of the ACS880 wind turbine converter variants by ABB are equipped with automatic software-controlled dry-out procedure, that sends dry-out requests to turbine PLC automatically. The turbine PLC needs to be pre-programmed to be able to handle the converter dry-out requests and send heating requests to cooling system heater.

  • Page 127: 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 www.abb.com/searchchannels.
  • Page 128 3AXD50000813605A © Copyright 2021 ABB. All rights reserved. Specifications subject to change without notice.

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