—

ABB WIND TURBINE CONVERTERS

ACS880-87LC-3328A/4100A-7 wind turbine

converters
Hardware manual
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List of related documents
General manuals Code (English)
Drive/converter/inverter safety instructions 3AXD50000037978
ACS880-77LC/-87LC wind turbine converters system 3AXD50000022022
description
ACS880-87LC-3328A/4100A-7 wind turbine converters 3AXD50000028543
safety instructions
ACS880-87LC-3328A/4100A-7 wind turbine converters 3AXD50000028542
hardware manual
ACS880-87LC-3328A/4100A-7 wind turbine converters 3AXD50000028545
start-up guide
ACS880-87LC-3328A/4100A-7 wind turbine converters 3AXD50000031295
firmware manual
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.

 Hardware manual
ACS880-87LC-3328A/4100A-7 wind turbine converters

Table of contents

3. Mechanical installation

5. Electrical installation

 2019 ABB Oy. All Rights Reserved. 3AXD50000028542 Rev E

EN
EFFECTIVE: 2019-01-14
 5

Table of contents

1. Introduction to the manual

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Purpose of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Contents of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Categorization by frame size and option code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Quick installation, commissioning and operation flowchart . . . . . . . . . . . . . . . . . . . . . . . 13
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2. Operation principle and hardware description

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Generator control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Overview diagram of the wind turbine converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Layout drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Overview of power and control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
BAMU board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Smoke detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Type designation labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Type designation key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Basic code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Option codes (plus codes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3. Mechanical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Checklist before mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Moving the converter package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Moving the converter package by fork-lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Lifting the converter package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Moving the converter on rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Lifting the converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Placing the converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Fastening the cabinet to the floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Internal cooling circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
DC chopper (option +D150) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Lifting the door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Cable duct in the floor below the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Electric welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Removing the lifting bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Installing the capacitor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6

Installing the DC resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Installing the lead-through box for generator cables . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Installing the lead-throughs for grid cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

4. Planning the electrical installation

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Selecting the grid disconnecting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Checking the compatibility of the generator and the converter . . . . . . . . . . . . . . . . . . . 50
Protecting the generator insulation and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Sufficient conductivity of the protective conductor . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Typical power cable sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Power cable types for limited use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Not allowed power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Generator cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Single core vs multicore cables in grid cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Additional US and Canada requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Armored cable / shielded power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Selecting the DC resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Resistor sizing (no option +D151) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Resistor cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Relative heat energy accumulated in DC resistors . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Relay cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Protecting the converter installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Protecting the grid cable in short-circuit situations . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Protecting the generator and generator cable in short-circuit situations . . . . . . . . . . 58
Protecting the converter, generator cable and grid cable against thermal overload . 58
Protecting the converter against ground faults in the generator or generator cable . 58
Protecting the converter against ground faults in the converter or grid cable . . . . . . 58
Implementing the emergency stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Implementing the grid fault ride-through function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Supplying power for the auxiliary circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Using a safety switch between the converter and generator . . . . . . . . . . . . . . . . . . . . . 60
Protecting the contacts of relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

5. Electrical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Grid cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Generator stator and generator cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
User-defined DC resistor and resistor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Connecting the grid cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
 7

Connecting the generator cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Connecting the external power supply cable for the auxiliary circuit . . . . . . . . . . . . . . . . 67
Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Default I/O connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Connecting a DC resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Measuring the resistance of the DC resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

6. Installation checklist
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Before you start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

7. Maintenance
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Maintenance timers and counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Replacing the cooling fan of the converter module . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Replacing the fan of the main breaker cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Replacing the upper cooling fan of the main breaker cubicle . . . . . . . . . . . . . . . . . . . 83
Replacing the cooling fan of the auxiliary control cubicle . . . . . . . . . . . . . . . . . . . . . . 84
Replacing the upper cooling fan of the LCL filter cubicle . . . . . . . . . . . . . . . . . . . . . . 86
Replacing the lower cooling fan of the LCL filter cubicle . . . . . . . . . . . . . . . . . . . . . . 88
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Replacing the DC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Replacing the AC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Replacing the DC chopper fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Replacing the clamping filter fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Converter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Replacing the converter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
BCU control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Replacing the memory unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Replacing the real-time clock battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Replacing the SD/SDHC memory card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Replacement illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Main circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Checking the pH of the coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Smoke detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Testing the smoke detectors with test smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Replacing the smoke detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

8. Technical data
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
8

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Type equivalence table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Main circuit AC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Main circuit DC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Fuses for the voltage measurement board BAMU . . . . . . . . . . . . . . . . . . . . . . . . . 109
Fuses for the clamping filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Dimensions, weights and free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Losses, cooling data and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Internal cooling circuit data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Terminal and lead-through data for the grid connection . . . . . . . . . . . . . . . . . . . . . . . 110
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Terminal and lead-through data for the generator cable . . . . . . . . . . . . . . . . . . . . . . . 111
Grid specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Requirements for the grid connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Generator connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
DC chopper (option +D150) and DC resistor connection data . . . . . . . . . . . . . . . . . . 112
DC chopper fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
DC resistor data (per one resistor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
BCU control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Environmental and corrosion classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Auxiliary circuit current consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
ACS880-87LC-3328A/4100A-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
UPS supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Non-UPS supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Compliance with the European Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . 115
Compliance with the European EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Regulatory Compliance Mark (RCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
EAC marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Compliance with EN 61800-3:2004/A1:2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Category C4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
ETL marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
DNV-GL Renewable Certification marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
WEEE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Disclaimers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Generic disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Cybersecurity disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

9. Control units of the converter

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
BCU control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
 9

Layout and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

BCU layout and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Control unit connector data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

10. Dimension drawings

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

11. Cooling and heating

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Diagram of the internal cooling and heating circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Planning the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Connection to a customer cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
General requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Coolant temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Connecting the internal cooling circuit to a customer cooling unit . . . . . . . . . . . . . . 132
Connecting the liquid pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Filling up and bleeding the internal cooling circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Converters with a customer cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Draining the internal cooling circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Cooling station control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
ACU heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
ACU dry-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Booting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Faulted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Converter heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Converter dry-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
State diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Manual control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Temperature limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Pressure limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Water quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Freeze protection and corrosion inhibition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Coolant concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Liquid mixture quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Approved coolants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Further information
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
10
 Introduction to the manual 11

1
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. The flowchart refers to chapters/sections in this manual and other manuals.

Safety instructions
See ACS880-87LC-3328A/4100A-7 wind turbine converters safety instructions
(3AXD50000028543 [English]).

Target audience
This manual is intended for people who plan the installation, install, commission, use and
service the converter. Read the manual before working on the converter. The reader is
expected to know the fundamentals of electricity, wiring, electrical components and
electrical schematic symbols.
The manual is written for readers worldwide.

Purpose of the manual

This manual helps in planning the installation, installing, using and servicing the converter.
12 Introduction to the manual

Contents of the manual

• Operation principle and hardware description
• Mechanical installation
• Planning the electrical installation
• Electrical installation
• Installation checklist
• Maintenance
• Technical data
• Control units of the converter
• Dimension drawings
• Cooling and heating

Related documents
See List of related documents on the inside of the front cover.

Categorization by frame size and option code

This manual deals with the wind turbine converters made of the modules of the frame size
R9iLC. The frame size of each converter type is indicated in section Type equivalence
table on page 108.
The instructions, technical data and dimensional drawings which concern only certain
optional selections are marked with + codes. The options included in the converter can be
identified from the + codes visible on the type designation label. The + code selections are
listed in chapter Operation principle and hardware description under Type designation key.
 Introduction to the manual 13

Quick installation, commissioning and operation

flowchart
Task See

Plan the installation. Check: ambient conditions, Technical data, page 107
ratings, required external cooling circuit arrangements, Planning the electrical installation, page 49
compatibility of the generator, power cable connection,
Option manuals (if optional equipment is included)
etc.
Select the cables.

Unpack and check the equipment. Checklist before mechanical installation, page 28
Check the type code indicated on the type designation
label against the original order.

Check that all necessary option modules and

equipment are present and correct.

Only intact converters may be started up!

Check the installation site. Checklist before mechanical installation, page 28

Route the cables. Routing the cables, page 57

Move the converter to the installation site and attach it Mechanical installation, page 27
to the floor.

Connect an external cooling circuit to the converter. Cooling and heating, page 129

Check the insulation of the generator and the generator Checking the insulation of the assembly, page 61
cable.

Connect the power cables. Connect the control and the Electrical installation, page 61
auxiliary control cables.

Check the installation. Installation checklist, page 71

Commission the converter. Start-up guide and firmware manual

14 Introduction to the manual

Terms and abbreviations

Term/abbreviation Explanation

Auxiliary voltage switch Main switch for the auxiliary voltage

Auxiliary control cubicle The cubicle with auxiliary devices such as auxiliary voltage circuit breakers,
(ACU) control electronics, measurement boards, etc.

BAMU Main voltage measurement board

BCON Type of control board

BCU Type of control unit, a BCON board in a metal housing. See BCON.

DC chopper Protects the converter by cutting down a peak overvoltage in the converter DC
link: conducts the surplus energy from the intermediate circuit of the wind
turbine converter to the DC resistor when necessary. The chopper operates
when the DC link voltage exceeds a maximum limit. A sudden disturbance in
turbine operation or grid can cause the DC voltage rise.

DC resistor Dissipates the surplus energy conducted by the DC chopper to heat. Essential
part of the chopper circuit. See DC chopper.

CCU Control cubicle

Control board Circuit board in which the control program runs. See BCON.

Control unit Control board built in a rail-mountable housing. See BCU.

Converter Converts direct current and voltage to alternating current and voltage, or vice
versa.

Converter module Grid-side converter or generator-side converter module

Cubicle One section of a cabinet-installed wind turbine converter. A cubicle is typically

behind a door of its own.

DC link DC circuit between grid-side converter and generator-side converter

DC link capacitors Energy storage which stabilizes the intermediate circuit DC voltage.

DDCS Distributed drives communication system; a protocol used in optical fiber

communication

DTC Direct torque control; a generator control method by ABB.

EMC Electromagnetic compatibility

FCAN Optional CANopen® adapter module

FEA Optional extension adapter module

FEN-31 Optional HTL incremental encoder interface module

FENA Optional Ethernet adapter module for EtherNet/IP™, Modbus TCP® and
PROFINET IO® protocols

FIO-01 Optional digital I/O extension module

FIO-11 Optional analog I/O extension module

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.
 Introduction to the manual 15

Term/abbreviation Explanation

Generator-side The converter part that is connected to the generator stator and controls the
converter generator operation. It converts the AC power from the generator to the
converter DC bus.

Grid-side converter A converter that is connected to the grid and is capable of transferring energy
from the converter DC link to the grid and vice versa.

I/O Input/Output

IGBT Insulated gate bipolar transistor; a voltage-controlled semiconductor type widely

used in various converters because of their easy controllability and high
switching frequency.

Intermediate circuit See DC link.

LCL filter Inductor-capacitor-inductor filter at AC side of the grid-side converter.

Attenuates harmonics.

Main circuit breaker Electrically-controlled main switching and protecting device. A withdrawable
breaker can also be used as the main disconnector.

MBC Main breaker cubicle containing main switching and disconnecting devices,
power terminals, etc.

NETA-21 Remote monitoring tool

Parameter User-adjustable operation instruction to the converter, or signal measured or

calculated by the converter.

PE Protective Earth

PLC Programmable logic controller

PSL Power stage link

R9iLC Converter module size, see Frame (size).

UPS Uninterruptible power supply

Wind turbine converter A converter for controlling AC generators in wind turbine applications.

Wind turbine system Wind turbine system consists of the wind turbine, wind turbine converter,
generator etc.

WTC Wind turbine controller. The wind turbine controller controls the whole wind
turbine system.

ZMU Memory unit attached to the BCU control unit connector X205 MEMORY UNIT.
16 Introduction to the manual
 Operation principle and hardware description 17

2
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. The converter is connected between the generator stator and the grid. The
converter can be installed up in the nacelle or down on the ground level.
The converter consists of back-to-back connected cubicles that contain the grid-side
converter modules, generator-side converter modules, LCL filter, terminals or grid busbars
for grid cables and generator cables, internal control circuits, external control cable
terminals, auxiliary circuits and external auxiliary power supply terminals.
18 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.
 =UMR
=01

=UMR+MWR =UMR+MWR =UMR+NWR =UMR+NWR

+11.1 +11.2 +01.1 +01.2
-FC1_2
=UMR+BWA
+02.1 =UMR+NWR
U4.1 +01.2
-F4.11-12

-R5.1
-R5.2
-R5.3
-R5.4
-R5.5
-R5.6
=UMR+BWB

-F5.13-14
-F5.23-24
-F5.33-34
-F5.43-44
+02.2 -F4.21-22

U4.2

=UMR+NWR
=UMR+BWC +01.1
+02.3
-F4.31-32
U4.3

-F5.21-22
-F5.31-32
-F5.41-42
-F5.51-52

-F5.11-12
-F5.61-62
=UMR+BWD -F4.41-42
+02.4 -T5.1 -T5.2 -T5.3 -T5.4 -T1.1 -T1.2 -T1.3 -T1.4 -T1.5 -T1.6
U4.4

=-RF1
+11.12 AC
CLAMP

-F1.11-13
-F1.21-23
-F1.31-33
-F1.41-43
-F1.51-53
-F1.61-63

FILTER
DC
=UMR+FIF =UMR+FKO
PE -F23 -F2.1_3 -F20.1_3 +01.4 +12.5
+R1

-K2
-C1 -C2

PE
-K1

=UMR+STF =UMR+NAF
+01.3 -X27.6 F11 K120:X8 +01.5 -R6 -F9
K518:X1 K51
-Q6 =EBR
=UMR+RES -XD001
+01.31 -F11
=BOB =EBR
=UMR -Q2 -XE001
-XD001 -F24.1_4 -F3.1_4
-F27.1_3

AUXILIARY
SUPPLY -F41 -Q1
400/230V AC =UMR -Q10
=UMR
-XG003
-XD002
UPS *
-F28.1_3

230V AC =UMR
-F25.1_2 -XG002
-F26 -F4
-F33 -TI.4-6
=GEN
=UMR -XG100 -F6.1_3 -F7.1_3
=UMR =UMR
-XF001
-XF002 -XG001
=KUM
-XG001 =KUM -TI.1-3
-XD001 to
A single-line diagram of the wind turbine converter is shown below.

-XD009
* *
*
SUB-D
connector
I/O
=KUM ETHERNET CONNECTIONS
CONVERTER
Overview diagram of the wind turbine converter

CU Generator Voltage
speed data measurement
=UMR
SIGNAL INTERFACE -XD021,
Encoder Current -XD041,
VOLTAGE SUPPLY measurement -XD061

=GEN
-XD021,
-XD041, LINE CONNECTION =UMR
-XD061 T -XE021
SQUIRREL CAGE INDUCTION 3x580VAC
MACHINE
=GEN CONNECTION
-XE021 3x750VAC
G
* - On the roof of the converter
Operation principle and hardware description 19
20 Operation principle and hardware description

Layout drawing
Layout of the wind turbine converter is shown below.

Front view

17

16 16
19

10

6 6 11 18
12

14
4 4 4 4
13
8

15

5 5 5 5

1 2 2 3

No. Description
1. Auxiliary control cubicle
2. Generator-side converter cubicles
3. Main breaker cubicle
4. Generator-side converter modules
5. DC fuses
6. Generator cable terminals [U2, V2, W2]
7. Main circuit breaker [Q1]
8. Grid cable terminals [L1, L2, L3]
9. Cooling fans of the main breaker cubicle
10. Upper cooling fan of the main breaker cubicle
11. Auxiliary voltage switch [Q2]
12. Charging circuit switch [Q10]
13. Overvoltage protection devices
14. BCU control units for the grid-side converter and generator-side converter
15. Cooling fan of the auxiliary control cubicle
16. Generator cable lead-throughs
17. Capacitor of the LCL filter
18. Auxiliary terminals
19. Clamping filter
 Operation principle and hardware description 21

Back view

12 12 12 12

4 13 14 13 14

10 10 10 10 10 10

6
8 8 8 8 8 8

11

5
9 9 9 9 9 9
7 15

1 2 2 3

No. Description
1. LCL filter cubicle
2. Grid-side converter cubicle
3. Control cubicle
4. Coolant out
5. Coolant in
6. Upper cooling fans of the LCL filter cubicle
7. Lower cooling fans of the LCL filter cubicle
8. Grid-side converter modules
9. Grid-side converter DC fuses
10. Grid-side converter AC fuses
11. Control cable terminals for customer connections
12. DC resistors
13. DC resistor fuses
14. DC resistor connections
15. Clamping filter fuses
22 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. The option module slots on the control unit are reserved for internal use
and communication.

FIO FXX FIO FXX

FXXX RDCO FXXX RDCO

CH0 CH1 CH2 CH3 CH0 CH1 CH2 CH3

Slots 1…3 Slots 1…3

RDCO (slot 4) RDCO (slot 4)

PSL PSL

BCON BCON

BCU control unit BCU control unit

External control via Ethernet

Both BCU control units are connected to Ethernet switch
L1 U2
L2 V2
L3 W2

Grid-side converter Generator-side converter

 Operation principle and hardware description 23

Circuit boards
For the interconnections between the control boards of the converter, see the circuit
diagrams.

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.

Smoke detector
The wind turbine converter is equipped with smoke detector to provide additional
protection. Smoke detector is located in the upper part of the incoming cubicle and the
signal is connected to K112:slot 3: DI2. The smoke detector is equipped with NC (normally
closed) contact which opens if smoke is detected.
Smoke detector alarm can be reset only with auxiliary power reboot. In case of smoke
detector alarm it is mandatory to check the converter for possible hardware related issues.
Especially LCL filter capacitor requires visual inspection and capacitance measurement
between phases.
24 Operation principle and hardware description

Type designation labels

The type designation label of the wind turbine converter is attached inside the cabinet
door. 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-3328A/4100A-7+C143+D150+F276
+H372+H373+K457+K464+L502+L520+P902+P911 2
3

6
FRAME 4
4×R9iLC 5
+6×R9iLC

7 1

2
3

ABB Oy
Hiomotie 13
00381 Helsinki 6
Finland 4
FRAME
R9iLC 5

Liquid cooling

7
IP00
UL open type
1
UL/CSA: max 810 VDC/600 VAC

No. Description

1 Serial number. The first digit of the serial number refers to the manufacturing plant. The next four
digits refer to the converter’s manufacturing year and week, respectively. The remaining digits
complete the serial number so that there are no two converters with the same number.

2 Type code. See section Type designation key.

If the delivery contains a DC chopper, option code +D150 is marked in the converter label.
 Marking with the Single mark of product circulation on the market of the Customs Union member
states

Operation principle and hardware description 25

No. Description

3 Valid markings. Possible markings are, for example:

• CE marking

• EAC marking

• UL marking

• RCM marking

• WEEE marking

See chapter Technical data.

4 Ratings of the converter

5 Number and frame size of the converter modules.

In the upper label for the ACS880-87LC converter, there are four generator-side converter modules,
six 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.

6 Manufacturing location

7 Information about cooling, IP class etc.

Type designation key

The type code of the wind turbine converter contains information on the specifications and
configuration.
• The first 23 digits form the basic code. It describes the basic construction of the wind
turbine converter. The fields in the basic code are separated with hyphens.
• The option codes follow the basic code. Each option code starts with an identifying
letter (common for the whole product series), followed by descriptive digits. The option
codes are separated by plus signs.
The selections are listed below. For more information, contact your local ABB
representative.
26 Operation principle and hardware description

 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. Grid-side converter current rating

25 Voltage rating 7 7 – Voltage range 525…690 V. This is

indicated in the type designation label as a
typical input voltage level (3~ 690 V AC).

 Option codes (plus codes)

Code Description
I/O options
L502 FEN-31 HTL incremental encoder interface module
Fieldbus
K457 FCAN-01 CANopen adapter module
Ethernet
K464 NETA-21 remote monitoring tool (EIP, MB/TCP)
Construction
C143 Cooling connections on the right side (when looking the converter from the main breaker
cubicle side)
H372 Cable conduit entry for 1-phase cabling – generator cable (3·10·[27…35] mm +
10·[27…35] mm PE)
H373 Cable conduit entry for 1-phase cabling – grid cable (3·10·[27…35] mm + 10·[27…35] mm PE)
L520 Fast connector plugs for I/O terminals
Grid control options
D150 DC chopper
D151 DC resistor
F276 Grid fault ride-through
Documentation language (delivered set may include documents in English)
R701 German
R707 French
Specialities
P902 Customized (described in Technical Appendix)
P911 Extended warranty
 Mechanical installation 27

3
Mechanical installation

Contents of this chapter

This chapter describes the mechanical installation procedure of the wind turbine converter.

Safety instructions
See ACS880-87LC-3328A/4100A-7 wind turbine converters safety instructions
(3AXD50000028543 [English]).
28 Mechanical installation

Checklist before mechanical installation

The installation site

Check the installation site. See section Ambient conditions on page 113 for the allowed operating
conditions, and section Dimensions, weights and free space requirements on page 109 for the
requirements for free space around the converter.
Check that the floor that the converter is installed on is of non-flammable material, as smooth as
possible, and strong enough to support the weight of the converter.
Check the floor flatness with a spirit level. The maximum allowed deviation from the surface level is
5 mm (0.2 in) in every 3 meters (9.8 ft).
If necessary, level the installation site, as the cabinet is not equipped with adjustable feet.
Check that the wall behind the converter is of non-flammable material.

Required tools
Check that you have following tools for moving the converter to its final position, fastening it to the
floor and tightening the connections:
• crane or fork-lift (check the load capacity); iron bar and piece of planked wood
• Pozidriv and Torx (2.5 … 6 mm, 0.98 … 0.2 in) screwdrivers for the tightening of the frame screws
(Screws needed for fastening the cabling boxes and other accessories delivered by ABB are
included in the delivery. They are inside the cabinet. The delivery does not contain screws or tools
to install the cabinet to the floor.)
• torque wrench
• set of wrenches and sockets.

The delivery
For unpacking the delivery, see page 30.
Check that the delivery contains:
• converter cabinet
• cabling boxes for the generator-side converter
• option modules (installed at the factory)
• DC chopper(s) and DC resistor(s) (optional)
• appropriate wind turbine converter manual(s) and option module manual(s)
• delivery documents (dimension drawings, circuit diagrams, etc.)
• lifting bars (see disassembly instructions starting on page 35)
• LCL capacitors (see assembly instructions starting on page 37)
• DC resistor adapters (see assembly instructions starting on page 42).
• accessories for cable lead-throughs (see assembly instructions starting on page 45).
The manual(s) are delivered inside the converter.
Check that there are no signs of damage.
Check the information on the type designation label of the converter to verify that the delivery is of
correct type.
 Mechanical installation 29

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.
• Do not tilt. The center of gravity is high.
• Move only in the upright position.

Moving

Pulling Pushing
30 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. Cut the attachment clamps with side cutters and pull them away.
2. Remove the fastening screws/nails/rivets and unpack the converter from the wooden
package.
3. Cut the plastic covering the converter with a carpet knife and remove it.
4. Detach the converter from its platform, lift the converter and remove the platform.
 Mechanical installation 31

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.

WARNING! Divide the weight to all lifting bars and all holes. If you do not divide
the load evenly, the lifting bars can not carry the weight of the converter.

2. Tighten the slings steadily and make sure that the load is evenly divided.
3. Lift steadily.
4. Position the converter as near its final position as possible.
5. Remove the lifting bars and refasten the roof bolts to retain the degree of protection of
the cabinet. Store the loose lifting bars for later use.

Lifting the converter

a
32 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.

The cabinet has a back-to-back design, and thus you cannot install it with a longer side
against a wall.
The converter must be installed in an upright vertical position.
Notes:
• Leave a 400 mm (16 in) clearance above the converter cabinet to allow pressure
release lids to open in an arc fault situation.
• Leave space at the side for the coolant pipes.
• You can adjust the height, for example, if the floor is uneven by using metal shims
between the cabinet frame and floor.

> 400 mm (16 in)

 Mechanical installation 33

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 34).

Internal cooling circuit

For installations related to cooling, see chapter Cooling and heating on page 132.

DC chopper (option +D150)

Option +D150: There is a DC chopper with no ABB-installed DC resistor. The customer
connects a customer-acquired DC resistor at the installation site.
• Arrange sufficient cooling and mechanical protection (eg, shrouds) for the DC resistor
assembly.
• Do not install the DC resistors near flammable materials.
• You can assemble the DC resistors eg, on top of the converter cabinet.
34 Mechanical installation

Lifting the door

1. Open the handles.
2. Detach the upper part of the door.
3. Lift the door upwards.

1 2 3

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). The cabinet weight lies on the 100 mm (4 in) wide sections in front, middle and
back which the floor must carry.
Prevent the cooling air flow from the cable duct to the cabinet by bottom plates. To ensure
the degree of protection for the cabinet use the original bottom plates delivered with the
converter. With user-defined cable entries, take care of the degree of protection, fire
protection and EMC compliance.

 Electric welding
It is not recommended to fasten the cabinet by welding. If you must do it for some reason:
• Weld only the flat bar under the cabinet, never the cabinet frame itself.
• Clamp the welding electrode onto the flat bar about to be welded or to the next flat bar
of the cabinet (within 0.5 meters of the welding point).

WARNING! If the welding return wire is connected improperly, the welding circuit
may damage electronic circuits in the cabinet. The thickness of the zinc coating of
the cabinet frame is 100 … 200 micrometers; on the flat bars the coating is
approximately 20 micrometers. Ensure that the welding fumes are not inhaled.
 Mechanical installation 35

Removing the lifting bars

1. Remove lifting bars 3AUA0000118772 with 3AUA0000062977, 27898157 M16×50
screws, 3AXD50000013704 M16 spring washers, 26380766 M16 washers and
27044271 M16 nuts.

3AUA0000062977
8 pcs 27044271
Nut M16 24 pcs
3AUA0000118772
26360766
4 pcs
washer M16 48 pcs
3AXD50000013704
spring washer M16 24 pcs

27898157
M16×50 screw 24 pcs
36 Mechanical installation

2. Remove lifting bars 3AXD50000026342 with 3AXD50000013597 M16×40 screws,

3AXD50000013704 M16 spring washers, 26380766 washers and 64595091 M16
gaskets. Store the screws for later use.

3AXD50000013597
M16×40 screw, 28 pcs

26380766 3AXD50000013704
washer M16, 28 pcs spring washer M16, 28 pcs

Lifting bars 3AXD50000026342

64595091
4 pcs
gasket M16, 28 pcs
 Mechanical installation 37

Installing the capacitor unit

1. Remove the transportation cover (3AXD50000028594). Remove the plug screws M6 8
pcs (36623110, 68578850, 68452317). Remove the cover of the connection hole
3AXD50000027957.

Drawing: 3AXD50000028520
BOM: 3AXD50000028594

3AXD50000027957

36623110
68578850
68452317

2. Install the capacitor unit.

The capacitor unit is pre-assembled.

The mass of the capacitor unit: 155 kg (341.7 lb)

The capacitor unit is hoisted to be installed.

The max. angle between ropes is 60°.

Max.
60°

Drawing: 3AXD50000031185
BOM: 3AXD50000031073
38 Mechanical installation

Install M6 gasket 2+2=4 pcs

M6×16 combiscrew 2+2=4 pcs
Tighten the screws later.

Install M6 gasket 5+5=10 pcs

M6 combiscrew 5+5=10 pcs
Tighten the screws, torque 9 N·m (6.6 lbf·ft).

Connect the busbar with

M12×35 screw 3 pcs
M12 spring washer 3 pcs
M12 washer 3 pcs
Tighten the screws, torque 70 N·m (52 lbf·ft).

3. Connect the temperature measuring wires.

3
 Mechanical installation 39

4. Install the front cover and the connection cover.

3AXD50000027970

Install the front cover with M6 gasket 10 pcs

M6×16 combiscrew 10 pcs
Tighten the screws, torque 9 N·m (6.6 lbf·ft).

3AXD50000027957

Install the front cover with M6 gasket 10 pcs

M6×16 combiscrew 10 pcs
Tighten the screws, torque 9 N·m (6.6 lbf·ft).
40 Mechanical installation

5. Install the box and cover.

Lift the box to install.

The mass of the capacitor unit cover: 20 kg (44 lb)

Drawing: 3AXD50000028957
BOM: 3AXD50000031074

Install M6 gasket 3+3=6 pcs

M6×16 combiscrew 3+3=6 pcs
Tighten the screws, torque 9 N·m
(6.6 lbf·ft).

Tighten the screws 2+2=4 pcs,

torque 9 N·m (6.6 lbf·ft).
 Mechanical installation 41

Install M6 gasket 13 pcs

M6×16 combiscrew 13 pcs
Tighten the screws, torque 9 N·m (6.6 lbf·ft).

Install 3AXD50000028068 with M6 gasket

18 pcs 3AXD50000028068
M6×16 combiscrew 18 pcs
Tighten the screws, torque 9 N·m (6.6 lbf·ft).
42 Mechanical installation

Installing the DC resistors

1. Remove the covers 3AXD50000027506 with 36623101 combiscrews.

3AXD50000027506
2 pcs
36623101
M6×12 combiscrew
28 pcs
68578850
28 pcs

2. Connect the resistor cables with M10×25 combiscrews (8 pcs). Tighten the screws,
torque 42 N·m (31 lbf·ft).

3. Tighten the M32 cable glands 3AXD50000031112 and locking nuts 68336945.

3AXD50000031112 8 pcs
68336945 8 pcs
 Mechanical installation 43

4. Install the cover 3AXD50000027506 with M6×12 combiscrews. Tighten the screws,
torque 9 N·m (6.6 lbf·ft).

3AXD50000027506
2 pcs
36623101
M6×12 combiscrew
28 pcs
68578850
28 pcs

5. Assemble the support frame. Tighten the screws, torque 42 N·m (31 lbf·ft).

3AXD50000027689

3AXD50000027691
4 pcs
3AXD50000027686

68343143
M10×16 combiscrew 16 pcs

6. Assemble the resistors with the support frame. Tighten the screws, torque 42 N·m
(31 lbf·ft).

Max. Hoist the resistor to install with the support frame.

60° The max. angle between ropes is 60°.
FAY3121802_SW resistor
4 pcs

68310857
M10×25 combiscrew 16 pcs
44 Mechanical installation

7. Install the support frame with the resistors to the roof top.

Hoist the support frame with the resistors and

install to the roof.
The maximum angle between the ropes: 45°.
The mass of the resistor unit: 220 kg (485 lb).
Turn the lifting eyes toward force axis
before hoisting.
Max.
3AXD50000013597 45°
M16×40 screw 24 pcs, re-use.
Tighten the screws, torque,
120 N·m (89 lbf·ft).
3AXD50000013704
M16 spring washer
24 pcs, re-use.
26380766
M16 washer 24 pcs,
re-use.

64595091
M16 gasket 24 pcs
Only unused gaskets
are allowed.

Additionally, fix the roof with 4 pcs of M16 screws, washers and gaskets in the middle of the cabinet. Re-
use the detached M16 fastenings.

8. Connect the cables (8 pcs) between the resistor and converter frame. Tighten the
screws, torque 42 N·m (31 lbf·ft).

27044239 M10 hex nut 8 pcs

26379288 M10 washer 16 pcs
29542708 M10 cup washer 8 pcs

27897312 M10 hex screw 8 pcs

.

27897312 M10 hex screw 8 pcs

29542708 M10 cup spring 8 pcs

26379288 M10 washer 8 pcs
 Mechanical installation 45

Installing the lead-through box for generator cables

1. Remove the covers (3AXD50000027658 and 3AXD50000128426) with 68578850 and
36623110 combiscrews.

Cover 3AXD50000128426 Cover 3AXD50000027658

68578850
M6 gasket, 38 pcs

36623110
M6×16 combiscrew, 36623110
68578850
38 pcs M6×16 combiscrew, 28 pcs
M6 gasket, 28 pcs

2. Install the generator-side roof boxes (3AXD50000027891, 3AXD50000134694 and

3AXD50000136162) with 68578850 and 36623110 combiscrews. Tighten the screws,
torque 9 N·m (6.6 lbf·ft).

Drawing: 3AXD50000136162 Drawing: 3AXD50000134694 Drawing: 3AXD50000027891

BOM: 3AXD50000136322 BOM: 3AXD50000136001 BOM: 3AXD50000030681

68578850
M6 gasket, 26 pcs
36623110
M6×16 combiscrew, 68578850
26 pcs M6 gasket, 28 pcs
36623110
M6×16 combiscrew, 28 pcs
46 Mechanical installation

3. Install the covers (3AXD50000030459 and 3AXD50000133468). Install 40 pcs M50

cable glands 3AXD50000027887. Re-tighten the covers with 68578850 and 36623128
combiscrews, torque 9 N·m (6.6 lbf·ft).

36623128 M6×20 combiscrew

Cable glands 24 pcs
3AXD50000027887 68578850 M6 gasket
40 pcs 24 pcs

Cover Cover
3AXD50000133468 3AXD50000030459

4. Connect 2 pcs PE cables 3AXD50000034332 between generator lead-through box

and converter frame. Tighten the screws, torque 22 N·m (16.2 lbf·ft).

26379245 M8 washer
27044182 M8 hex nut.
2 pcs
2 pcs

29542783 M8 cup spring

29542783 M8 cup spring 2 pcs
2 pcs

26379245 M8 washer 10237866 M8×20 hex screw

2 pcs 2 pcs

3AXD50000034332
2 pcs
 Mechanical installation 47

Installing the lead-throughs for grid cables

1. Open the doors and remove the plate 3AXD50000026897 with 68343071 combiscrew.
Remove the plate 3AXD50000031773 with 36623110 combiscrews.

3AXD50000026897
36623110 M6×16
2 pcs
combiscrew
68343071 M4×12 18 pcs
combiscrew 3AXD50000031773
8 pcs
48 Mechanical installation

2. Open the doors and install Roxtec 3AXD50000027645 and 3AXD50000027650.

3. Install 40 pcs cable glands 3AXD50000027887.
4. Re-tighten the plate with 36623110 combiscrews, torque 9 N·m (6.6 lbf·ft).

3AXD50000027650 3AXD50000027645 36623110 M6×16 combiscrew

2 4 18 pcs

3AXD50000027889
40 pcs
3AXD50000031773

3 3AXD50000027887 40 pcs
 Planning the electrical installation 49

4
Planning the electrical
installation

Contents of this chapter

This chapter contains the instructions that you must follow when selecting the generator,
cables, protections, cable routing and way of operation for the converter system.
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.

Selecting the grid disconnecting device

The converter is equipped with a main circuit breaker as standard. The breaker is
withdrawable: when withdrawn (cranked out), the breaker operates as a main
disconnector for the converter. However, the withdrawn main circuit breaker does not
isolate the grid cable terminals of the converter from the grid. Equip the installation with
another disconnecting device placed in between the power grid and the grid cable
terminals of the converter. For example, the main circuit breaker of the grid transformer
could also be used as the extra disconnecting device if it meets the requirements for a
disconnecting device.
50 Planning the electrical installation

Checking the compatibility of the generator and the

converter
The converter is compatible with induction generators and permanent magnet generators.
1. Select the generator according to the ratings table in chapter Technical data on
page 107.
2. Check that the generator and the converter have the same voltage rating. Check also
that the voltage ratings match the voltage to be connected to the grid-side converter.
Note: You can rise the converter DC link voltage 10% of its natural level (by a
parameter setting). The effect is equivalent to a 10% voltage rise at the generator
terminals. Before you use this feature, make sure that the generator insulation can
withstand the higher voltage level.

When the generator voltage rating

should be
DC bus voltage is not increased from nominal (default) UN
DC bus voltage is increased from nominal by parameter setting UACeq

UN rated grid-side voltage of the converter

UACeq equivalent grid-side voltage of the converter in V AC, UACeq = UDC / 1.41

UDC maximum DC bus voltage of the converter in V DC. You can set the voltage reference with
parameter in grid-side converter control program for 1.1 · 1.41 · UN at maximum. You can set the
reference to a lower value but the program restricts it to a value of at least 1.41 · UN.

3. Make sure that the generator is suitable for the converter use, ie, it can withstand the
voltage peaks at of the converter:
• Use insulated N end (non-driven end) bearing in the generator.
• Make sure that the generator insulation meets the requirements in the table below.
• Select the cables according to the instruction in this manual.
• Install the converter and its cabling as instructed in this manual.

 Protecting the generator insulation and bearings

The generator-side converter output of the wind turbine converter comprises – regardless
of output frequency – pulses of approximately the converter DC bus voltage with a very
short rise time. This is the case with all converters employing modern IGBT technology.
The voltage of the pulses can be almost double at the generator terminals, depending on
the attenuation and reflection properties of the generator cable and the terminals. This in
turn can cause additional stress on the generator and generator cable insulation.
Modern variable speed converters with their fast rising voltage pulses and high switching
frequencies can cause current pulses that flow through the generator bearings, which can
gradually erode the bearing races and rolling elements.
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:
• du/dt filter protects generator insulation system and reduces bearing currents
• common mode filter mainly reduces bearing currents
• clamping filter reduces voltage peaks.
 Planning the electrical installation 51

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
Dimension the grid cable or busbar and generator cable according to local regulations:
• The cable must be able to carry the converter load current. See chapter Technical
data on page 107 for the rated currents.
• The cable must be rated for at least 90 °C (194 °F) maximum permissible temperature
of conductor in continuous use. See also section Additional US and Canada
requirements on page 54.
• The inductance and impedance of the PE conductor/cable (grounding wire) must be
rated according to permissible touch voltage appearing under fault conditions (so that
the fault point voltage will not rise excessively when a ground fault occurs).
• The rated voltage between the conductors of the cable should be minimum 1 kV.
For generators, the symmetrical shielded generator cable is highly recommended. See
section Alternative power cable types on page 52.
Note: When continuous conduit is employed, shielded cable is not required.
Note: When using a four-conductor system, consult the generator manufacturer regarding
bearing and disturbance shielding.
In a non-symmetrical four-conductor system, voltage can be induced to the separate PE
conductor, which rises generator frame potential and causes current to ground through the
generator bearings and shaft. This causes extra wear. Whereas, in a symmetrical shielded
cable, the high capacitance between the PE conductor and the phase conductors forms an
LC filter reducing bearing currents and voltage changes.
A four-conductor system is allowed for grid cabling, but shielded symmetrical cable is
highly recommended.

 Sufficient conductivity of the protective conductor

The protective conductor must always have an adequate conductivity.
Unless local wiring regulations state otherwise, the cross-sectional area of the protective
conductor must agree with the conditions that require automatic disconnection of the
supply required in 411.3.2. of IEC 60364-4-41:2005 and be capable of withstanding the
prospective fault current during the disconnection time of the protective device.
The cross-sectional area of the protective conductor can either be selected from the table
below or calculated according to 543.1 of IEC 60364-5-54.
52 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.
Cross-sectional area of the phase conductors Minimum cross-sectional area of the
2 corresponding protective conductor
S (mm )
Sp (mm2)
S < 16 S
16 < S < 35 16
35 < S < 400 S/2
400 < S < 800 200
800 < S S/4

Compared to a four-conductor system, the use of symmetrical shielded cable reduces

electromagnetic emission of the whole converter system as well as generator bearing
currents and wear.
The generator cable and its PE pigtail (twisted screen) should be kept as short as possible
in order to reduce electromagnetic emission as well as capacitive current.

 Typical power cable sizes

See the Technical appendix.

 Alternative power cable types

The power cable types that you can use with the converter are shown below.

PE Symmetrical shielded cable with three phase conductors and a concentric PE

conductor as shield. The shield must meet the requirements of IEC 61800-5-1.
Check with local / state / country electrical codes for allowance.

Symmetrical shielded cable with three phase conductors and a concentric PE

conductor as shield. A separate PE conductor is required if the shield does not
meet the requirements of IEC 61800-5-1.
PE

Symmetrical shielded cable with three phase conductors and symmetrically

PE
constructed PE conductor, and a shield. The PE conductor must meet the
requirements of IEC 61800-5-1.

Power cable types for limited use

A four-conductor system (three phase conductors and a protective conductor on

PE
a cable tray) is not recommended for cabling.
 Planning the electrical installation 53

Not allowed power cable types

A four-conductor system (three phase conductors and a PE conductor in a PVC

conduit)
PVC

Corrugated cable with three phase conductors and a protective conductor or

cable in EMT conduit
EMT

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
PE
not allowed on any cable size for grid and generator cabling.

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. The
requirements are easily met with a copper or aluminum shield. The minimum requirement
of the generator cable shield of the converter is shown below. It consists of a concentric
layer of copper wires with an open helix of copper tape or copper wire. The better and
tighter the shield, the lower the emission level and bearing currents.

1 2 3 4 5

1 Insulation jacket
2 Helix of copper tape or copper wire
3 Copper wire screen
4 Inner insulation
5 Cable core
54 Planning the electrical installation

 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.
The table below shows three possible cabling options.
No. Layout Description
1 Multicore cabling (recommended). See subsection
Alternative power cable types for the possible
constructions of the PE (protective earth/ground).

2 Single core cables in trefoil (preferable single core cabling

L1 L2 L3 option).
L2 L3 L3 L1 L1 L2

3 Single core cables laid flat.

L1 L2 L3 PE L1 L2 L3 PE

 Additional US and Canada requirements

Use copper, copper-clad aluminum or aluminum conductors. Use conductors rated for
75 °C (167 °F) only.
Run the cabling in metallic conduits, or use type MC continuous corrugated aluminum
armor cable with symmetrical grounds or shielded power cable for the generator cables if
metallic conduit is not used.

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.
Note: Do not run generator wiring from more than one converter in the same conduit.
Armored cable / shielded power cable
6-conductor (3 phases and 3 ground) type MC continuous corrugated aluminum armor
cable with symmetrical grounds is available from the following suppliers (trade names in
parentheses):
• Anixter Wire & Cable (Philsheath)
• BICC General Corp (Philsheath)
• Rockbestos Co. (Gardex)
• Oaknite (CLX).
Shielded power cables are available from Belden, Lapp Kabel (ÖLFLEX) and Pirelli,
among others.
 Planning the electrical installation 55

Selecting the DC resistors

For the technical data of the DC resistors, see page 112.

 Resistor sizing (no option +D151)

These instructions describe how to select and plan the installation of the DC resistors for
those deliveries which do not include them as factory-installed (no option +D151).
• Ensure that the resistance value is within the allowed minimum and maximum values
defined for the chopper circuit. See chapter Technical data.
• Select a resistor with power rating that exceeds the maximum power rating. See
chapter Technical data.
• Ensure that the resistor withstands the energy pulse during the load cycle. If you do
not know the load cycle, contact your local ABB representative.
• Ensure that the resistor inductance value is less than 10 μH.

 Resistor cabling
Keep the DC resistor cable as short as possible in order to minimize the EMC emissions
and stress on the DC chopper IGBTs. The longer the cable, the higher the inductive load
and voltage peaks over the IGBT semiconductors of the DC chopper.
The DC resistor and DC resistor cables are protected by the chopper DC fuses. Therefore
resistor cable short-circuit protection is handled by them as long as the cable is
dimensioned properly according to the chopper current. When customer-installed resistor
and resistor cable are used (converter with no option +D151), ensure that the DC resistor
cable conductor size is equal or exceeds the specified minimum conductor size. See
chapter Technical data.

DC resistor cable (per one resistor)

Minimum conductor size Al (mm²) Minimum conductor size Cu (mm²)
50 35

 Relative heat energy accumulated in DC resistors

The BCU control unit calculates the actual relative heat (0%…100%) accumulated in a DC
resistor. The calculation is based on a thermal model with a single time constant. When
the function is on, heat accumulates in the resistor. When the function is off, heat
dissipates and the DC resistor cools down. When the actual relative heat value is 100%,
the DC resistor has reached its maximum temperature rise. The value is calculated based
on the resistor parameters.
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. The other end of the shield should be left unconnected or grounded
indirectly via a high frequency, high voltage capacitor of a few nanofarads. The screen can
also be grounded directly at both ends if they are in the same earth line with no significant
voltage drop between the end points.
56 Planning the electrical installation

Use a double shielded twisted pair cable (see figure a) for analog signals. This type of
cable is recommended for the pulse encoder signals as well. Employ one individually
shielded pair for each signal. Do not use common return for different analog signals.
A double shielded cable is the best alternative for low voltage digital signals but single
shielded twisted multipair cable (figure b) is also acceptable.

a b
Double-shielded twisted pair cable Single-shielded twisted multipair cable

Run analog and digital signals in separate, shielded cables.

Relay-controlled signals, providing their voltage does not exceed 48 V, can be run in the
same cables as digital input signals. It is recommended to run the relay-controlled signals
as twisted pairs.
Never mix 24 V DC and 115 / 230 V AC signals in the same cable.

 Relay cable
The cable type with braided metallic screen (for example, ÖLFLEX from Lapp Kabel,
Germany) has been tested and approved by ABB.
 Planning the electrical installation 57

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.
Where control cables must cross power cables make sure they are arranged at an angle
as near to 90° as possible. Do not run extra cables through the converter.
The cable trays must have good electrical bonding to each other and to the grounding
electrodes. You can use aluminum tray systems to improve local equalizing of potential.
A diagram of the cable routing is below.

Generator cable
Converter
min. 300 mm (12 in)
Power cable

Grid cable Generator cable

min. 200 mm (8 in) 90° min. 500 mm (20 in)

Control cables

 Control cable ducts

24 V 230/120 V 24 V 230/120 V

Not allowed unless the 24 V cable is insulated Lead 24 V and 230/120 V control cables
for 230 V (120 V) or insulated with an in separate ducts into the inside of the
insulation sleeving for 230 V (120 V). cabinet.
58 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

situations
The converter protects the generator cable and the generator in a short-circuit situation
when the generator cable is sized according to the nominal current of the converter. No
additional protection devices are needed.

 Protecting the converter, generator cable and grid cable against

thermal overload
The converter protects itself, the grid cables and generator cables against thermal
overload when the cables are sized according to the nominal current of the converter and
ambient conditions are within the limits specified under Ambient conditions on page 113.
No additional thermal protection devices are needed.

 Protecting the converter against ground faults in the generator or

generator cable
Both the grid-side converter and generator-side converter are equipped with an internal
ground fault protective function to protect them against ground faults in the converter itself,
the generator and generator 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.

 Protecting the converter against ground faults in the converter or

grid cable
Both the grid-side converter and generator-side converter are equipped with an internal
ground fault protective function to protect them against ground faults in the converter itself
and 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.
 Planning the electrical installation 59

Implementing the emergency stop function

The converter is equipped with subsystems which can be used to implement the
emergency stop, stop category 0 function:
• Emergency stop push buttons on the cabinet doors of the auxiliary control cubicle and
the control cubicle (see chapter Dimension drawings).
• The main circuit breaker (and relays controlling the breaker), which can be used as the
actuator subsystem in the safety function.
The emergency stop function is to be implemented, wired and verified by the customer. A
logic subsystem (safety relay; safety PLC) must be added to the circuit. Appropriate
standards (EN ISO 13850; EN ISO 13849 or EN 62061; EN 60204-1) must be applied.
According to EN 13850, the emergency stop function shall achieve at least Safety Integrity
level 1 (SIL 1) or Performance Level c (PL c).
Note: In the ACS880-87LC converter delivery, a contact of the emergency stop push
buttons are wired into the digital inputs of the control boards by ABB on customer's
request. These connections cannot be used in the safety-related control of the actuator of
emergency stop functions, it can only be used for indication purposes. Similarly, the stop
implemented by the ACS880-87LC control board is a non-safety related stop. A safety-
related relay or PLC must be used to control the main circuit breaker in the safety-related
stop. See the circuit diagrams delivered with the converter.
For safety reasons, install the emergency stop devices at each operator control station
and at other operating stations where emergency stop may be needed.

WARNING! Because there is no safety relay installed in the emergency stop

circuit of the wind turbine converter, the converter does not comply with the
Machinery Directive requirements for emergency stop. Make sure that the
aforementioned requirements are fulfilled and the emergency stop circuit functions
properly before commissioning the converter.

Implementing the grid fault ride-through function

See the firmware manual.

Supplying power for the auxiliary circuits

The converter is not equipped with an auxiliary voltage transformer. Always connect an
external auxiliary power supply. For the power rating, see section Auxiliary circuit current
consumption on page 114.
As standard, the converter auxiliary circuit is to be supplied from the electrical power
network through an external transformer.
The converter is equipped with connectors for 3-phase 400 V AC non-uninterruptible
power supply, and 230 V AC uninterruptible power supply. The customer has to supply
uninterruptible power from an external on-line power supply.
60 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.

Protecting the contacts of relay outputs

Inductive loads (such as relays, contactors and generators) cause voltage transients when
switched off.
The relay contacts of the control board are protected with varistors (250 V) against
overvoltage peaks. In spite of this, it is highly recommended to equip inductive loads with
noise attenuating circuits (varistors, RC filters [AC] or diodes [DC]) in order to minimize the
EMC emission at switch-off. If not suppressed, the disturbances may connect capacitively
or inductively to other conductors in the control cable and form a risk of malfunction in
other parts of the system.
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

 Electrical installation 61

5
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.

See the circuit diagrams delivered with the converter. The diagrams of this chapter do not
necessarily match the installation-specific circuit diagrams of a tailor-made wind turbine
converter.

Checking the insulation of the assembly

WARNING! See and obey the safety instructions of the converter. If you ignore
them, injury or death, or damage to the equipment can occur.

 Converter
Do not make any voltage tolerance or insulation resistance tests (for example, hi-pot or
megger) on any part of the converter as testing may damage the converter. Every
converter has been tested for insulation between the main circuit and the chassis at the
factory. Also, there are voltage-limiting circuits inside the converter which cut down the
testing voltage automatically.
62 Electrical installation

 Grid cable
Check the insulation of the grid cable according to local regulations before connecting it to
the converter.

 Generator stator and generator cable

Check the insulation of the generator stator and cable as follows:
• Check that all cables are disconnected from the converter output terminals U2, V2 and
W2.
• 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 or 77 °F). For
the insulation resistance of other generators, please consult the manufacturer’s
instructions.
• Note: Make sure that there is no condensed moisture inside the generator casing. If
you suspect that there is moisture, dry the generator before measurement.
• Note: When using permanent magnet generator, it must be stable at the time of the
measurement.

U1
G
V1
3~
ohm W1
PE

 User-defined DC resistor and resistor cable

Option +D150: There is a DC chopper with no ABB-installed DC resistor. The customer
connects a customer-acquired DC resistor at the installation site.
• Check that the resistor cable is connected to the resistor and disconnected from the
converter output terminals R+ and R-. At the converter end, connect the R+ and R-
conductors of the resistor cable together.
• Measure the insulation resistance between the conductors and the PE conductor by
using a measuring voltage of 1 kV DC. The insulation resistance must be higher than
1 Mohm.

R+

R-
ohm

PE
 Electrical installation 63

Connecting the grid cables

 Connection diagram

PE U<

L1
L2
L3

PE
64 Electrical installation

 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. Obey the grease manufacturer’s instructions.
Aluminum-aluminum contact can cause oxidation in the contact surfaces.

1. Open the door of the main breaker cubicle. Unlock the handle, release it from the
holder and turn upwards to release the door locking mechanism.
2. Remove the shroud that protects the grid cable terminals.
3. Lead the grid cables into the inside of the cubicle.
4. Fasten the grid cables to the grid connection terminals. Connect the phase conductors
to terminals L1, L2 and L3. Tighten the conductors to 120 N·m (89 lbf·ft). Tightening
torques are also given in chapter Technical data.
5. Connect ground conductors or cables to the cabinet PEN (ground) busbar.
6. Provide support for the connections whenever necessary.
7. Refit all shrouds removed earlier.
8. Close the door.
 Electrical installation 65

Connecting the generator cables

 Connection diagram

PE

U2
V2
U1
V1
G
W2 W1 3~
PE

 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. Obey the grease manufacturer’s instructions.
Aluminum-aluminum contact can cause oxidation in the contact surfaces.

1. Open the door of the generator cable connection cubicle (see figures on the next
page).
2. Remove the shroud that protects the generator cable connection busbars and cable
entries.
3. Ensure that foreign objects (screws, etc.) cannot fall inside the converter module.
During installation, cover the top of the module with plastic, fabric etc.

WARNING! Foreign objects inside the converter module can cause eg, short-
circuit. Injury or death, or damage to the equipment can occur.

4. When shielded cable is used:

• Lead the cables into the inside of the cubicle. Ground a shielded cable 360° at the
lead-through with an EMC cable gland (to be supplied by the customer).
• Connect the cables as follows:
• Cut the cables to suitable length. Strip the cables and conductors. Fasten the
cable lugs to the conductor ends.
• Twist the cable shields into bundles and connect to the cabinet PE (ground)
busbar. Connect any separate ground conductors or cables to the cabinet PE
(ground) busbar.
• Connect the phase conductors to terminals U2, V2 and W2. See the appropriate
connection diagram above. Tighten the phase conductors and PE to a 120 N·m
(89 lbf·ft) torque.
66 Electrical installation

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. Tighten the phase and PE conductors (see
page 110).
5. Provide support for the cables whenever necessary.
6. Remove the cover on top of the converter module.

WARNING! The cover on top of the converter module can cause

overheating. Injury or death, or damage to the equipment can occur.

7. Refit the shroud removed earlier and close the door.

8. Connect the generator end of the cable. For minimum radio frequency interference
and generator bearing current, ground the cable shield 360° at the lead-through of the
generator terminal box. For the generator specific instructions, see the manufacturer’s
user manual.

8 Cable shield grounding means at the generator end

360° grounding of the shield

 Electrical installation 67

Connecting the external power supply cable for the

auxiliary circuit
Power supply terminals for the auxiliary circuit are located in the upper part of the main
breaker cubicle (see section Layout drawing on page 20). See the circuit diagrams
delivered with the converter, and section Auxiliary circuit current consumption on
page 114.

Auxiliary connection
box
68 Electrical installation

Connecting the control cables

Control cable connectors are located in the lower part of the control cubicle and on the
cabinet roof (see section Layout drawing on page 20). See the circuit diagrams delivered
with the converter.
 Electrical installation 69

Control connections
in the lower part of
the control cubicle

Control connections
on the roof of the
control cubicle

3 2 1

Connector Description
UMR-XD001 Auxiliary supply 400/230 V AC
UMR-XD002 UPS 230 V AC (located on the cabinet roof) (1)
KUM-XG001 Signal interface (located on the cabinet roof) (2)
KUM-XD001 Voltage supply
KUM-XD002 Voltage supply
KUM-XD003 Voltage supply
KUM-XD004 Voltage supply
KUM-XD005 Voltage supply
KUM-XD006 Voltage supply
KUM-XD007 Voltage supply
KUM-XD008 Voltage supply
KUM-XD009 Voltage supply
UMR-XF001 SUB-D connector
UMR-XF002 Ethernet
UMR-XG001 I/O connections (located on the cabinet roof) (3)
UMR-XG002 Current measurement
UMR-XG003 Voltage measurement
70 Electrical installation

 Default I/O connection diagrams

See the circuit diagrams delivered with the converter.

Connecting a PC
See the start-up guide.

Connecting a DC resistor
Option +D150: There is a DC chopper with no ABB-installed DC resistor. The customer
connects the customer-acquired DC resistor at the installation site.

 Connection procedure
1. Lead the resistor cable in through the roof of the cubicle.
2. Seal the lead-through properly to resume the degree of protection.
3. Connect the conductors to R+ and R- terminals.

 Measuring the resistance of the DC resistor

Test the DC resistor installation by measuring:
1. Measure the resistance of each DC resistor from the cabinet DC resistor connectors
(see the figure below).
2. Make sure that the resistance value is within the allowed minimum and maximum
values defined for the chopper circuit (see page 112).
 Installation checklist 71

6
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. Do the tasks described in the safety instructions of the converter. If you
ignore them, injury or death, or damage to the equipment can occur.

1. Open the main disconnector of the converter and lock it to open position.
2. Ensure by measuring that the converter is not powered.
72 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.

All bleed and drain valves have been closed.

The internal cooling circuit has been filled with coolant that meets the specification. See section
Specifications on page 139.

The internal cooling circuit has been bleeded. See section Filling up and bleeding the internal cooling
circuit on page 133.

There is an adequately sized protective earth (ground) conductor between the converter and the main
grounding busbar of the wind turbine.

The generator is properly grounded.

All protective earth (ground) conductors have been connected to the appropriate terminals and the
terminals have been tightened (pull the conductors to check).

The voltage of the grid transformer matches the nominal voltage of the grid-side converter. Check the
type designation label.

The grid cable or grid busbars have been connected to the appropriate terminals, the phase order is
right, and the terminals have been tightened. (Pull the conductors to check.) For tightening torques,
see section Tightening torques on page 110.

The generator cable has been connected to the appropriate terminals, the phase order is right, and
the terminals have been tightened. (Pull the conductors to check.) For tightening torques, see section
Tightening torques on page 110.

The generator cable (and DC resistor cable, if present) has been routed away from other cables.

Converters which have a DC chopper (option +D150) with a customer-acquired and installed DC
resistor: The DC resistor has been installed, connected to the appropriate terminals, and the
terminals have been tightened. (Pull the conductors to check.)
Test the DC resistor installation by measuring. Measure the resistance of each DC resistor from the
cabinet DC resistor connectors. Ensure that the resistance value is within the allowed minimum and
maximum values defined for the chopper circuit (see page 112).
 Installation checklist 73

Make sure that …

The control cables have been connected to the appropriate terminals, and the connections are tight.
(Pull the conductors to check.)
Check and connect the following terminals:
• UMR-XD001
• UMR-XD002
• KUM-XG001
• KUM-XD001
• KUM-XD002
• KUM-XD003
• KUM-XD004
• KUM-XD005
• KUM-XD006
• KUM-XD007
• KUM-XD008
• KUM-XD009
• UMR-XF001
• UMR-XF002
• UMR-XG001
• UMR-XG002
• UMR-XG003

The capacitor unit of the LCL filter has been connected to the appropriate terminals, and the terminals
have been tightened. (Pull the conductors to check.) For tightening torques, see section Tightening
torques on page 110.
Test the LCL filter installation by measuring. Measure the LCL filter capacitance symmetrically in each
phase in the grid-side converter cubicle. The capacitance should be about 990 μF.

There are no tools, foreign objects or dust from drilling inside the converter.

All shrouds and cover of the generator connection box are in place. Cabinet doors have been closed.

The converter is ready for start-up.

74 Installation checklist
 Maintenance 75

7
Maintenance

Contents of this chapter

This chapter contains preventive maintenance intervals and instructions.
76 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
0 1 2 3 4 5 6 7 8 9 10 11 12 …
Replacement
Cooling fans R R
Cooling fan power supply R
Water-glycol coolant with inhibitor I I R I I R
(see Note 1 below)
Electrolytic capacitors (DC circuit), if R
used (see Note 2 below)
ABB-SACE main circuit breaker P P P P P P P P P P/ P P
maintenance (see Note 3 below) R

BDPS, BINT, BGDR and flat cables R

Control unit battery R R
Smoke detectors R
Inspection and/or performance
Checking the pH of the coolant P P P P P P
Adding coolant corrosion inhibitor (if I P I P I P I P I P I P
coolant with separate inhibitor is used)
(see Note 1 below)
Checking cooling liquid pipe connections I I I I I I I I I I I I
Checking the connections of fiber optic I I I I
cables
Checking tightness of cable and busbar P P P P
terminals. Tightening if needed.
Checking the quick connector of the I I I I
converter module
Checking the condition of contactors I I I I I I I I I I I I
Checking the condition of the main I I I I I I I I I I I I
contactors (maintenance according to
the manufacturer’s instructions)
Checking ambient conditions (dustiness, I I I I I I I I I I I I
corrosion, temperature)
Checking the quality of auxiliary voltage I I I I I I I I I I I I
Testing the smoke detectors with test I I I I I I I I I I I I
smoke
Improvements
Firmware and hardware upgrade based I I I I I I I I I I I I
on product notes
Measurements and tests
Functional test with net voltage P P P P P P P P P P P P
Basic measurements with supply voltage P P P P P P P P P P P P
Spare parts
Spare part stock I P I P I P I P I P I P
3AXD10000258568
 Maintenance 77

Symbols
I Inspection (visual inspection and maintenance action if needed)
P Performance of on/off-site work (commissioning, tests, measurements or other work)
R Replacement

Maintenance and component replacement intervals are based on the assumption that the equipment is
operated within the specified ratings and ambient conditions. ABB recommends annual inspections to ensure
the highest reliability and optimum performance.
Long term operation near the specified maximum ratings or ambient conditions may require shorter
maintenance intervals for certain components. Contact your local ABB Service representative for additional
maintenance recommendations.
Note 1: Cooling liquid to be used is Antifrogen N mixed with tapwater. For more details, see chapter Cooling
and heating. In case practical examples or specific tests carried with the above mentioned cooling mixture
together with the cooling system materials the maintenance interval can be revised.
Note 2: The capacitor lifetime and the resulting maintenance interval can be calculated based on the
operational, ambient and environmental conditions.
Note 3: The maintenance schedule of the main circuit breaker is according to maximum 1,000 operations of
the breaker per each year. Replacement after 6000 operations. For more information, refer to the maintenance
manual of the ABB SACE breaker.

Maintenance timers and counters

The control program has maintenance timers or counters that can be configured to
generate a warning when a pre-defined limit is reached. Each timer/counter can be set to
monitor any parameter. This feature is especially useful as a service reminder. For more
information, see the firmware manual.
78 Maintenance

Power connections
 Tightening

WARNING! Only qualified electricians are allowed to do this work. Read the
complete safety instructions of the converter. If you ignore the instructions,
physical injury, death, or damage to the equipment can occur.

1. Disconnect the converter from the all power sources and make sure it is safe to start
the work. See the safety instructions.
2. Check the tightness of the cable connections. Use the tightening torques given in
chapter Technical data.

Fans
The lifespan of the cooling fans of the converter depend on the running time of the fan,
ambient temperature and dust concentration. See the firmware manual for the parameter
or actual value which indicates the running time of the cooling fan of the converter
modules. For resetting the 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.
 Maintenance 79

 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. Disconnect the converter from the all power sources and make sure it is safe to start
the work. See the safety instructions.
2. Cooling fan of the converter module (a) is located on top of the module. Open the door
of the converter module cubicle and remove the shroud in front of the fan.
3. Disconnect the wiring plug of the fan (b).
4. Remove the fastening screws (c) of the fan support.
5. Lift the fan unit out of the cabinet.
6. Detach the fan from the support plate by loosening the fastening screws of the fan.The
fan grille is detached then too.
7. 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). Remember to install the fan
grille before lifting the fan into the cabinet.
80 Maintenance

2 3
a

Air flow direction

6
 Maintenance 81

 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. Disconnect the converter from the all power sources and make sure it is safe to start
the work. See the safety instructions.
2. Detach the shroud in front of the fan of the main breaker cubicle.
3. Pull the shroud carefully out of the cabinet. Observe the cable rail on top of the main
circuit breaker when removing the shroud.
4. Disconnect the wiring plug of the fan.
5. Remove the fastening screws of the plate in front of the fans and remove the plate.
6. Remove the fastening screws of the fan support plate and pull the support plate and
the fan out.
7. Remove the fastening screws of the fan grille (M4×60, 4 pcs) and detach the fan grille
together with the fan.
8. Replace the fan.
9. 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).
82 Maintenance

Air flow
direction
 Maintenance 83

 Replacing the upper cooling 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. Disconnect the converter from the all power sources and make sure it is safe to start
the work. See the safety instructions.
2. Remove the shroud in front of the upper cooling fan.
3. Disconnect the wiring plug in front of the fan support plate.
4. Remove the fastening screws of the fan support plate and pull the support plate and
the fan out.
5. Remove the fastening screws of the fan and detach the fan.
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).

Air flow direction

4
5
84 Maintenance

 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. Disconnect the converter from the all power sources and make sure it is safe to start
the work. See the safety instructions.
2. The cooling fan of the auxiliary control cubicle is located in the lower part of the
cubicle. Open the door of the auxiliary control cubicle.
3. Disconnect the wiring plug of the fan.
4. Undo the four fastening screws of the fan.
5. Pull the fan out.
6. Install a new fan in reverse order. Check that the air flow direction is correct (an arrow
indicating the direction is marked on the side of the fan). For the correct air flow
circulation, see the picture below.

Air flow
direction
 Maintenance 85

Air flow circulation

86 Maintenance

 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. Disconnect the converter from the all power sources and make sure it is safe to start
the work. See the safety instructions.
2. Open the door of the LCL filter cubicle. The upper cooling fans of the LCL filter cubicle
are attached to the metal plate.
3. Disconnect the wiring plug of the fan (a).
4. Undo the fastening screws of the fan (b).
5. Pull the fan out.
6. Install a new fan in reverse order. Check that the air flow direction is correct (an arrow
indicating the direction is marked on the side of the fan). In this case, the air flow
direction is towards the inner part of the cabinet.
 Maintenance 87

Air flow direction, side

view of the cubicle

Upper
cooling
fans

Door of the LCL

filter cubicle
88 Maintenance

 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. Disconnect the converter from the all power sources and make sure it is safe to start
the work. See the safety instructions.
2. Open the door of the LCL filter cubicle. There are three cooling fans in the lower part
of the cubicle.
3. Disconnect the wiring plugs (3 pcs, a) of the fans and detach the thermostat (B27, b).
4. Remove the fastening screws (M6, 6 pcs, c) and pull the fan cassette out.

b
a

2 c
 Maintenance 89

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.

7 Arrow indicating the air flow direction

90 Maintenance

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. Disconnect the converter from the all power sources and make sure it is safe to start
the work. See the safety instructions.
2. Remove the shrouds in front of the fuses.
3. Open the M10 screws and remove the fuses.
4. Insert new fuses.
5. Re-assemble the parts in reverse order. The tightening torque for the M10 screws is
42 N·m (31 lbf·ft).

2
3
 Maintenance 91

 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. Disconnect the converter from the all power sources and make sure it is safe to start
the work. See the safety instructions.
2. Remove the shrouds in front of the fuses.
3. Open the M10 screws and remove the fuses.
4. Insert new fuses.
5. Re-assemble the parts in reverse order. The tightening torque for the M10 screws is
42 N·m (31 lbf·ft).

3
92 Maintenance

 Replacing the DC chopper 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.

The DC chopper fuses are located in the top part of the grid-side converter cubicle. See
section Layout drawing on page 20.
1. Disconnect the converter from the all power sources and make sure it is safe to start
the work. See the safety instructions.
2. Remove the shrouds in front of the fuses.
3. Open the nuts and remove the fuses.
4. Insert new fuses.
5. Re-assemble the parts in reverse order. Tightening torque for the M10 screws is
42 N·m (31 lbf·ft).

3
 Maintenance 93

 Replacing the clamping filter 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.

The clamping filter fuses are located in the lower part of the grid-side converter cubicle.
See section Layout drawing on page 20.
1. Disconnect the converter from the all power sources and make sure it is safe to start
the work. See the safety instructions.
2. Remove the sealing ring.
3. Detach the screws and nuts.
4. Remove the insulation cover and the insulation sheet.
5. Detach the bolts and remove the fuse.
6. Re-assemble the parts in reverse order. Tightening torque for the M10 joint is 42 N·m
(31 lbf·ft). Make sure that you install the fuse in the correct position: the indicator
towards the cable end.

3
5

6
94 Maintenance

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:

• The modules are heavy and have a high center of gravity. They topple over easily if
handled carelessly.
• When removing a module, pull the module carefully out of the cubicle along the
installation stand. Prevent the module from falling.
• Keep your fingers away from the edge of the module front plate to avoid pinching them
between the module and the cubicle.
• Use protective gloves! The edges of the module are sharp!
• Beware not to drop the screws inside the module!
• Do not tilt the module. Do not leave the module unattended on a sloping floor.

1. Disconnect the converter from the all power sources and make sure it is safe to start
the work. See the safety instructions. Secure the main circuit breaker [Q1] to the
disconnected (racked out) position. If the disconnecting equipment is located outside
the cabinet, make sure that it is in the disconnected position.
Close the inlet and outlet valves of the liquid cooling unit, and drain the cooling circuit.
See section Draining the internal cooling circuit on page 134.
2. Open the door of the module cubicle.
 Maintenance 95

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.

4 4

6 6 6

5 5 5

4
4

7. Remove the pipe clamps from top tubes.

7
96 Maintenance

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.
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.

11 11
10

12
12
11 11

11
 Maintenance 97

13. Open Taptite® M6 screw on the floor.

13

14. Open the installation stand (optional) and place it in front of the module.

14
98 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).

15

15

15
 Maintenance 99

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.

16

17. Pull the module out a bit (5 cm [20 in]) and install the lifting hook to the lifting hole.

17
100 Maintenance

18. Pull the whole module onto the installation stand. Keep the pipes and wires away from
the sharp edges and be careful not to damage the coolant connections.
19. Lift the module onto a pallet or other platform for transportation.
20. Install a new module in reverse order. Tightening torque for cooling connectors is
10 N·m (7.4 lbf·ft) in room temperature (around +20 °C [68 °F]).

Capacitors
The converter intermediate circuit employs film capacitors. Their lifespan depends on the
operating time of the converter, loading and ambient temperature. Capacitor life can be
prolonged by lowering the ambient temperature.
Capacitor failure is usually followed by the converter module and module fuse failure, or a
fault trip. Contact ABB if capacitor failure is suspected. Replacements are available from
ABB. Do not use other than ABB specified spare parts.
 Maintenance 101

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.

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

 Replacing the memory unit

The memory unit is located on the BCU control unit.

WARNING! Do not remove or insert the memory unit when the control unit is
powered.

See b in figure Replacement illustration on page 102.

1. To remove the memory unit, undo the fastening screw and pull the memory unit out.
2. Insert the new memory unit and fasten the screw.

 Replacing the real-time clock battery

Replace the real-time clock battery if the BATT LED is not illuminated when the control unit
is powered.
See a in figure Replacement illustration on page 102.
1. Undo the fastening screw and remove the battery.
2. Insert the new battery according to figure Replacement illustration.
3. Dispose the old battery according to local disposal rules or applicable laws.
4. Set the real-time clock.

 Replacing the SD/SDHC memory card

Note: Do not remove the SD card while the yellow WRITE LED is lit. Writing to the SD
card is in progress.
See c in figure Replacement illustration on page 102.
1. Undo the fastening screw (Torx T10) of the clip covering the memory card and press
the card to remove it. For the card location, see the following figure.
2. Insert the new card in reverse order. Tightening torque for fastening screw is 0.7 N·m
(0.5 lbf·ft). Repeat the replacement procedure for other BCU control unit if needed.
102 Maintenance

 Replacement illustration

b A
2:1

aA
c
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).
 Maintenance 103

Checking the pH of the coolant

The coolant pH must be below 8.5. Measure the coolant pH every second year before you
possibly add inhibitor.
Note: The addition of inhibitor can temporarily increase the liquid pH level over the limits
specified in this manual. This depends on the water quality and is not harmful to the
system.
Keep a log of the test results.
1. If the pH is below 8.5, add only inhibitor in the internal cooling circuit. See section
Freeze protection and corrosion inhibition on page 140.
2. If the pH is between 8.5 and 9, replace the coolant.
If the pH is below 6 or more than 9, contact your local ABB representative for instructions
on how to flush the system and replace the coolant.
104 Maintenance

Smoke detectors
 Testing the smoke detectors with test smoke

WARNING! Only qualified electricians are allowed to do this work. Read the
complete safety instructions of the converter. If you ignore the instructions,
physical injury, death, or damage to the equipment can occur.

1. Disconnect the converter from the all power sources and make sure it is safe to start
the work. Only external control voltage can be supplied. See the safety instructions.
2. Wait for five minutes for the capacitors to discharge.
3. Remove the upper door of the incoming cubicle.
4. Remove the plug (M5).
5. Push the straw to the hole.
6. Spray test smoke. Follow the manufacturer’s instructions.
7. Check that the converter sets the fault: 5E63 Grid Smoke detector fault. Status of the
alarm can be checked also from K112:slot 3: DI2.
8. Clear the fault with auxiliary power reboot.
9. After test, save and write down the inspection date.
10. Fasten the plug.

Plug of hole for test smoke

 Maintenance 105

 Replacing the smoke detector

WARNING! Only qualified electricians are allowed to do this work. Read the
complete safety instructions of the converter. If you ignore the instructions,
physical injury, death, or damage to the equipment can occur.

1. Disconnect the converter from the all power sources and make sure it is safe to start
the work. See the safety instructions.
2. Wait for five minutes for the capacitors to discharge.
3. Unplug the connector XAI by pulling it upward.
4. Detach the five fixing screws (M6).
5. Pull the smoke detector kit out.
6. Detach the four fixing screws (M5) of the EMC cover.
7. Detach the EMC cover.
8. Remove the smoke detector by rotating.
9. Remove the base by detaching the two screws (M4).
10. Install a new base. See the delivery-specific circuit diagrams.
11. Install a new smoke detector by rotating.
12. Assemble and fasten the smoke detector kit in reverse order.
13. When the installation is complete, test the operation of the smoke detector. See
section Testing the smoke detectors with test smoke on page 104.
106 Maintenance

3 4

EMC cover

Smoke detector
 Technical data 107

8
Technical data

Contents of this chapter

This chapter contains the technical data of the ACS880-87LC-3328A/4100A-7.

Ratings
Converter type Generator-side converter Grid-side converter ratings Cos phi
ACS880-87LC- ratings
Pgen I2 Pgrid I1 Sn
kW A kW A kVA
UN = 580 V
3328A/4100A-7 3580 3328 4410 4100 4900 0.9
3AXD10000011539

Power flow:
• Grid-side converter (AC/DC): 4900 kVA
• Generator-side converter (DC/AC): 3978 kVA
108 Technical data

 Definitions
Generator-side converter ratings
UN Nominal voltage (see also section Grid specification on page 111)
Pgen Typical generator power. The power ratings apply at nominal voltage 690 V.
I2 Continuous rms current of the generator-side converter
Grid-side converter ratings
Pgrid Rated grid-side converter power. The power ratings apply at nominal voltage 690 V.
I1 Continuous rms current of the grid-side converter
Sn Apparent power
Cos phi Controllable cos phi with full rated power capacity. Range: -value…+value.

 Derating
The load capacity (current and power) decreases if the installation site altitude exceeds
1000 meters (3281 ft), or if the ambient temperature exceeds 45 °C (113 °F).

Temperature derating
In the temperature range +45 °C (+113 °F) … +55 °C (+131 °F), the rated output current is
decreased by 2.5 % for every additional 1 °C (1.8 °F). The output current is calculated by
multiplying the current given in the rating table by the derating factor.
Example If the ambient temperature is 55 °C (+131 °F), the derating factor is
100% - 2.5 % · 10 °C = 75% or 0.75. The output current is then 0.75 · Igen.
°C

Altitude derating
At altitudes from 1000 … 2000 m (3281 … 6562 ft) above sea level, the derating is 0.5%
for every 100 m (328 ft). Derating is allowed only on maximum continuous current for grid
and generator. If the installation site is 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. This means that in eg, 2000 m installation, the maximum liquid temperature
is 40 °C (instead of 50 °C) instead of 5% current derating.

Type equivalence table

Converter type Construction type Basic module type (R9iLC)
ACS880-87LC- Generator-side Grid-side
converter converter
Generator-side converter modules + ACS880-104LC- ACS880-104LC-
Grid-side converter modules+ LCL … (+E205) … (+E205)
UN = 580 V
3328A/4100A-7 4×R9iLC + 6×R9iLC + 1×LCL -0860A-7 -0800A-7
3AXD10000011539
 Technical data 109

Fuses
 Main circuit AC fuses
Converter type AC fuses
ACS880-87LC- Type IN Qty
A rms
UN = 580 V
3328A/4100A-7 Bussmann 170M6116 1250 18
3AXD10000011539

 Main circuit DC fuses

Converter type DC fuses
ACS880-87LC- Type IN Qty
A rms
UN = 580 V
3328A/4100A-7 Bussmann 170M6151 1400 20
3AXD10000011539

 Fuses for the voltage measurement board BAMU

The fuse type is Mersen cartridge fuse 1021 CP URB 27x60/32, 32 A
1000 V AC (IEC/UL); 2 pcs

 Fuses for the clamping filter

The fuse type is Bussmann 170M3141,100 A 1250 V AC; 2 pcs

Dimensions, weights and free space requirements

See also chapter Dimension drawings.
Converter type Dimensions Weight
ACS880-87LC- Height Depth Width
mm (in) mm (in) mm (in) kg (lb)
UN = 580 V
3328A/4100A-7 2000 (78.7) 1200 (47.2) 2400 (94.5) 4660 (9833)
3AXD10000011539

For free space requirements, see chapter Dimension drawings.

110 Technical data

Losses, cooling data and noise

Converter type Losses Cooling data Noise
ACS880-87LC- Liquid Air Coolant Mass flow Pressure loss
quantity (tolerance
-2%… +20%)
kW kW l l/min kPa dBA
UN = 580 V
3328A/4100A-7 155 3 50 280 100 < 70
3AXD10000011539

 Internal cooling circuit data

See chapter Cooling and heating.

Terminal and lead-through data for the grid connection

Each busbar consists of two parts placed against each other. You can connect cable lugs
to both sides of the connection busbar. Grid-side power connection enters the cabinet at
the bottom of the cabinet.

 Tightening torques
Screw size Torque

M5 4 N·m (3 lbf·ft)

M6 9 N·m (6.6 lbf·ft)

M8 22 N·m (16.2 lbf·ft)

M10 42 N·m (31 lbf·ft)

M12 70 N·m (52 lbf·ft)

M16 120 N·m (89 lbf·ft)

For the drawings and dimensions of the grid cable terminals, see chapter Dimension
drawings.
 Technical data 111

Terminal and lead-through data for the generator cable

You can connect cable lugs to both sides of the connection busbar. The lead-throughs are
acquired separately by the customer. Generator cables enter the cabinet at the top of the
cabinet.
Generator cable connection busbars are presented below. See also chapter Dimension
drawings.

Example fasteners for the customer cable lug:

Hex screw M16×40 (DIN 933 8.8)
Washer M16 (SFS 3738, 2 pcs)
Cup spring M16 (DIN 6796)
Hex nut M16 (DIN 934)

Grid specification
Voltage (U1) 525/550/575/580/600/660/690 V AC 3-phase for 690 V AC converters. This is
indicated in type designation label as typical input voltage level
(3~ 690 V AC).
±10% variation from the converter nominal voltage is allowed as default.
Frequency (f1) 50 ± 5 Hz or 60 ± 5 Hz. Maximum rate of change 17%/s.
Maximum allowable 75 kA when protected by fuses given under Fuses.
prospective short-circuit According to UL 508C, the converter is not rated for short-circuits with a
current (IEC 60439-1, power factor less than 1.
UL 508 C)
Power factor -1…0…1
Harmonic distortion Total harmonic current distortion (n = 2...40) < 5%.
Total harmonic voltage distortion (n = 2...40) < 5%, when Rsc > 7.

Requirements for the grid connection

For applicable grid codes, contact your local ABB representative.
112 Technical data

Generator connection data

Generator types AC induction generators, permanent magnet generators
Voltage (U2) 0 … 110% U1, 3-phase symmetrical, Umax 750 V
Output frequency (f2) 8…200 Hz
Switching frequency Grid-side converter: 2.6 kHz
Generator-side converter: 1.5 kHz
Frequency resolution 0.01 Hz
Current See section Ratings on page 107.
Field weakening point 8 … 300 Hz

DC chopper (option +D150) and DC resistor connection

data
Option +D150: There is a DC chopper with no ABB-installed DC resistor. The customer
connects a customer-acquired DC resistor at the installation site.
See also chapter Dimension drawings.

 DC chopper fuses
Type Qty
Bussmann 170M4243 2 per DC resistor

 DC resistor data (per one resistor)

Resistance 1.0 ohm
Nominal voltage (between live and earthed parts) 1300 V DC
Peak power (duration) 900 kW (3 s)
Continuous power 9 kW
Energy absorption capacity 2700 kWs

BCU control unit

See chapter Control units of the converter.

Efficiency
96.5% at nominal load with power factor 1.0 at 580 V.

Degree of protection
The converter is labeled as IP54, IP2x with cubicle doors open.

Environmental and corrosion classification

The expected lifetime for the converter cabinet enclosure is considered to be at least 20
years under the following environmental classifications and corrosion class.
Environmental classifications in accordance with IEC60721-3-3
• Climatic conditions 3K5 1)
 Technical data 113

• Special climatic conditions 3Z11 2)

• Chemically active substances 3C2
• Mechanically active substances 3S2
• Mechanical conditions 3M1
Corrosion class in accordance with 12944-1
• Corrosion class for the cabinet enclosure (painted surfaces, C3L3)
pre-treatment FeP, polyester powder paint thickness 80 µm)

Notes:
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 section Temperature derating on page 108.
3)
L denotes service life >15 years.

Disclaimer
The customer shall ensure that the environmental conditions inside the wind turbine is maintained in order to
fulfill the environmental classifications and/or corrosion class, as herein stated. If the operational condition is
out of any environmental classifications and/or corrosion class, the expected lifetime of the converter may be
risked and the 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.

Ambient conditions
Environmental limits for the converter are given below. The converter must be
used in a heated, indoor controlled environment.
Operation Storage Transportation
installed for stationary in the protective package in the protective package
use
Installation site altitude 0 … 1000 m (3281 ft) - -
above sea level. Above
1000 m (3281 ft), see
section Derating on page
108.
Air temperature -30 … +45 °C -40 … +70 °C -40 … +70 °C
(-22 … +113 °F) (with (-40 … +158 °F) (-40 … +158 °F)
heating procedure below
+5 °C before start-up)
Freezing of coolant is not
allowed. Above +45 °C
(+113 °F), see section
Derating on page 108.
Relative humidity 0 … 95% 0 … 95% 0 … 95%
No condensation allowed. Maximum allowed relative humidity is 60% in the
presence of corrosive gases.
Contamination levels No conductive dust allowed.
(IEC 60721-3-3, Boards with coating: Boards with coating: Boards with coating:
IEC 60721-3-2, Chemical gases: Class Chemical gases: Class Chemical gases: Class
IEC 60721-3-1) 3C2 1C2 2C2
Solid particles: Class 3S2 Solid particles: Class 1S3 Solid particles: Class 2S2
Atmospheric pressure 70 … 106 kPa 70 … 106 kPa 60 … 106 kPa
0.7 … 1.05 atmospheres 0.7 … 1.05 atmospheres 0.6 … 1.05 atmospheres
114 Technical data

Vibration (IEC 60068-2-6) 10…58 Hz, max. 10…58 Hz, max. Max. 3.5 mm (0.14 in.)
0.075 mm displacement 0.075 mm displacement (2 … 9 Hz),
amplitude amplitude max. 15 m/s2 (49 ft/s2)
58…150 Hz 10 m/s2 58…150 Hz 10 m/s2 (9 … 200 Hz) sinusoidal

Shock (IEC 60068-2-27) Not allowed Max. 100 m/s2 (330 ft/s2), Max. 100 m/s2 (330 ft/s2),
11 ms 11 ms
Free fall Not allowed 100 mm (4 in.) 100 mm (4 in.)

Materials
Cabinet Hot-dip zinc-coated (thickness approx. 20 µm) steel sheet (thickness 1.5 mm)
with polyester thermosetting powder coating (thickness approx. 80 µm) on
visible surfaces. Color: RAL 7035 (light beige, semi-gloss).
Color of the side panels: RAL 9017 (black, semi-gloss)
Busbars Tin- or silver-plated copper or aluminum
Internal cooling circuit Aluminum, acid-fast stainless steel, PA pipes
piping
Fire safety of materials Insulating materials and non-metallic items: Mostly self-extinctive
(IEC 60332-1)
Packaging Frame: Wood or plywood. Plastic wrapping: PE-LD. Bands: PP or steel.
Disposal The main parts of the converter can be recycled to preserve natural
resources and energy. Product parts and materials should be dismantled and
separated.
Generally all metals, such as steel, aluminum, copper and its alloys, and
precious metals can be recycled as material. Plastics, rubber, cardboard and
other packaging material can be used in energy recovery. Printed circuit
boards and large electrolytic capacitors need selective treatment according to
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.

Auxiliary circuit current consumption

Auxiliary circuit current consumption varies depending on the size of the converter and
selected options. For detailed information, contact your local ABB representative.

 ACS880-87LC-3328A/4100A-7
UPS supply
Voltage 230 V AC ± 5%, frequency 50 Hz or 60 Hz, typical power consumption 431 VA,
peak power and current consumption 8487 VA and 36.9 A.

Non-UPS supply
Voltage 400 V AC ± 5%, frequency 50 Hz or 60 Hz, typical continuous power consumption
6659.3 VA, maximum peak power consumption 41569 VA.
 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. Provisions for compliance: The final assembler of the machine is
responsible for installing
- an emergency-stop device.
• EN 60529:1991 Degrees of protection provided by enclosures (IP code)
• EN/IEC 61439:2011 Low-voltage switchgear and controlgear assemblies
• EN/IEC 60146 Semiconductor converters - General requirements and line commutated
converters
• EN/IEC 50178 Electronic equipment for use in power installations
• IEC 60664-1:2007 Insulation coordination for equipment within low-voltage systems. Part 1:
Principles, requirements and tests.
• IEC 61400-1:2005 Wind turbines. Part 1: Design requirements
• IEC 61800-3:2017 Adjustable speed electrical power drive systems. Part 3: EMC requirements and
specific test methods
• EN 61800-5-1:2007 Adjustable speed electrical power drive systems. Part 5-1: Safety requirements –
electrical, thermal and energy.
• BS7671 Requirements for electrical installations
• NEMA 250:2003 Enclosures for Electrical Equipment (1000 Volts Maximum)
• UL 61800-5-1 Adjustable Speed Electrical Power Drive Systems - Part 5-1: Safety Requirements
- Electrical, Thermal and Energy. See ETL marking on page 117.
• GL-IV-1:2010 Guideline for Certification of Wind Turbines
• CSA C22.2 No.274-13 Adjustable Speed Drives

CE marking
A CE mark is attached to the converter to verify that the converter follows the provisions of
the European Low Voltage Directive 2014/35/EU (previously 2006/95/EC) and EMC
Directive 2014/30/EU (previously 2004/108/EC).

 Compliance with the European Low Voltage Directive

The compliance with the European Low Voltage Directive has been verified according to
standard EN 61800-5-1.

 Compliance with the European EMC Directive

See section Compliance with EN 61800-3:2004/A1:2012.

Compliance with the European Machinery Directive

Note: In standard texts, the term 'drive' stands for 'converter' in case of wind turbine
applications.
The drive is an electronic product which is covered by the European Low Voltage
Directive. The drive is equipped with emergency stop push buttons and a main circuit
breaker with related relays, which can be used in implementing an emergency stop
function for machinery. This safety function is in the scope of the Machinery Directive as
safety component, and appropriate harmonized standards (EN ISO 13850, EN ISO 13849
or EN 62061) shall be applied.
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. Likewise,
the equipment must not disturb or interfere with any other product or system within its
locality.
First environment includes establishments connected to a low-voltage network which
supplies buildings used for domestic purposes.
Second environment includes establishments connected to a network not supplying
domestic premises.
Drive of category C4: drive of rated voltage equal to or above 1000 V, or rated current
equal to or above 400 A, or intended for use in complex systems in the second
environment.
 Technical data 117

 Category C4
The requirements of the standard can be met as follows:
1. It is ensured that no excessive emission is propagated to neighbouring low-voltage
networks. In some cases, the natural suppression in transformers and cables is
sufficient. If in doubt, the supply transformer with static screening between the primary
and secondary windings can be used.

Medium voltage network

Supply transformer

Neighbouring network
Static screen

Point of measurement

Low voltage Low voltage

Equipment
Converter
(victim)

Equipment 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.
WARNING! A drive of category C4 is not intended to be used on a low-voltage public
network which supplies domestic premises. Radio frequency interference is expected if
the converter is used on such a network.

ETL marking
cETLus certified.
The converters are ETL certified in accordance with UL 61800-5-1 Adjustable Speed
Electrical Power Drive Systems First Edition and CSA C22.2 No. 274-13 Adjustable Speed
Drive.
The converter provides overload protection in accordance with the National Electrical
Code (US) and Canadian Electrical Code (Canada). See the firmware manual for setting.
Default setting is off; the setting must be activated at start-up.
The converters are to be used in a heated indoor controlled environment. See section
Ambient conditions for specific limits.

DNV-GL Renewable Certification marking

This converter type is GL2010 Component Certified according to GL-IV-1:2010 Guideline
for Certification of Wind Turbines by DNV-GL, and is allowed to bear the DNV-GL
Renewable Certification mark (Certificate No. CC-GL-IV-1-00282-1):
• ACS880-87LC-3328A/4100A-7.
118 Technical data

WEEE marking
The converter is marked with the wheelie bin symbol. It indicates that at the end of life the
converter should enter the recycling system at an appropriate collection point and not
placed in the normal waste stream. See section Materials on page 114.

Disclaimers
 Generic disclaimer
The manufacturer shall have no obligation with respect to any product which (i) has been
improperly repaired or altered; (ii) has been subjected to misuse, negligence or accident;
(iii) has been used in a manner contrary to the manufacturer's instructions; or (iv) has
failed as a result of ordinary wear and tear.

 Cybersecurity disclaimer
This product is designed to be connected to and to communicate information and data via
a network interface. It is Customer's sole responsibility to provide and continuously ensure
a secure connection between the product and Customer network or any other network (as
the case may be). Customer shall establish and maintain any appropriate measures (such
as but not limited to the installation of firewalls, application of authentication measures,
encryption of data, installation of anti-virus programs, etc) to protect the product, the
network, its system and the interface against any kind of security breaches, unauthorized
access, interference, intrusion, leakage and/or theft of data or information. ABB and its
affiliates are not liable for damages and/or losses related to such security breaches, any
unauthorized access, interference, intrusion, leakage and/or theft of data or information.
 Control units of the converter 119

9
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.

General
 BCU control unit
The BCU control unit consists of a BCON control board (and a BIOC I/O and power supply
board) built in a metal housing. The BCU is mounted separately from the converter
module(s), and connected to the module(s) by fiber optic cables. In this manual, the name
“BCU” represents the control unit type BCU-12.
120 Control units of the converter

Layout and connections

 BCU layout and connections

Description
I/O 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
fieldbus adapter module connection
SLOT 3 I/O extension, encoder interface, fieldbus
adapter connection
SLOT 4 RDCO-0x DDCS communication option
module connection

X205 Memory unit connection

BATTERY Holder for real-time clock battery

AI1 Mode selector for analog input AI1

(I = current, U = voltage)
AI2 Mode selector for analog input AI2
(I = current, U = voltage)
D2D TERM Termination switch for drive-to-drive link
(D2D)
DICOM= Ground selection. Determines whether
DIOGND DICOM is separated from DIOGND (ie,
the common reference for the digital
inputs floats).

7-segment display
Multicharacter indications are displayed as repeated
sequences of characters
(“U” is indicated briefly before “o”.)
Control program startup in progress

(Flashing) Firmware cannot be started.

Memory unit missing or corrupted

Firmware download from PC to control

unit in progress

At power-up, the display may show short

indications of eg. “1”, “2”, “b” or “U”.
These are normal indications immediately
after power-up. If the display ends up
showing any other value than those
described, it indicates a hardware failure.
 Control units of the converter 121

Description
XAI Analog inputs
XAO Analog outputs
XDI 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 XAO
XPOW External power input
XRO1 Relay output RO1
XRO1 XRO2 Relay output RO2
XRO3 Relay output RO3
XDI XAI XSTO Not in use in wind turbine converters.
X485 XSTO OUT Not in use in wind turbine converters.
X12 Not in use in wind turbine converters.
X13 Control panel connection

XSTO X485 Not in use

XD2D XSTO
OUT
V1T/V1R, Fiber optic connection to converter modules 1
V2T/V2R and 2 (VxT = transmitter, VxR = receiver)
V3T/V3R Fiber optic connection to converter modules 3…7
… (BCU-12/22 only)
V7T/V7R (VxT = transmitter, VxR = receiver)
V8T/V8R Fiber optic connection to converter modules
… 8…12 (BCU-22 only)
V12T/V12R (VxT = transmitter, VxR = receiver)

SD CARD Data logger memory card for converter module

communication

BATT OK Real-time clock battery voltage is higher than

2.8 V. If the LED is off when the control unit is
powered, replace the battery.
FAULT The control program has generated a fault. See
the firmware manual.
PWR OK Internal voltage supply is OK
WRITE Writing to memory card in progress. Do not
remove the memory card.
122 Control units of the converter

Control unit connector data

Power supply Connector pitch 5 mm, wire size 2.5 mm2
(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 mm2
(XRO1…XRO3)
250 V AC / 30 V DC, 2 A
Protected by varistors
+24 V output Connector pitch 5 mm, wire size 2.5 mm2
(XD24:2 and XD24:4)
Total load capacity of these outputs is 4.8 W (200 mA / 24 V) minus
the power taken by DIO1 and DIO2.
Digital inputs DI1…DI6 Connector pitch 5 mm, wire size 2.5 mm2
(XDI:1…XDI:6) 24 V logic levels: “0” < 5 V, “1” > 15 V
Rin: 2.0 kohm
Input type: NPN/PNP (DI1…DI5), NPN (DI6)
Hardware filtering: 0.04 ms, digital filtering up to 8 ms
DI6 (XDI:6) can alternatively be used as an input for a PTC
thermistor.
“0” > 4 kohm, “1” < 1.5 kohm
Imax: 15 mA (DI1…DI5), 5 mA (DI6)
Start interlock input DIIL Connector pitch 5 mm, wire size 2.5 mm2
(XDI:7)
24 V logic levels: “0” < 5 V, “1” > 15 V
Rin: 2.0 kohm
Input type: NPN/PNP
Hardware filtering: 0.04 ms, digital filtering up to 8 ms
Digital inputs/outputs DIO1 and DIO2 Connector pitch 5 mm, wire size 2.5 mm2
(XDIO:1 and XDIO:2)
As inputs:
Input/output mode selection by 24 V logic levels: “0” < 5 V, “1” > 15 V
parameters. Rin: 2.0 kohm
DIO1 can be configured as a frequency Filtering: 1 ms
input (0…16 kHz with hardware filtering As outputs:
of 4 microseconds) for 24 V level square Total output current from +24VD is limited to 200 mA
wave signal (sinusoidal or other wave
form cannot be used). DIO2 can be +24VD
configured as a 24 V level square wave
frequency output. See the firmware
manual, parameter group 11/111.

DIOx

RL

DIOGND

Reference voltage for analog inputs Connector pitch 5 mm, wire size 2.5 mm2
+VREF and -VREF 10 V ±1% and –10 V ±1%, Rload 1…10 kohm
(XAI:1 and XAI:2) Maximum output current: 10 mA
Analog inputs AI1 and AI2 Connector pitch 5 mm, wire size 2.5 mm2
(XAI:4 … XAI:7) Current input: –20…20 mA, Rin = 100 ohm
Current/voltage input mode selection by Voltage input: –10…10 V, Rin > 200 kohm
switches. Differential inputs, common mode range ±30 V
Sampling interval per channel: 0.25 ms
Hardware filtering: 0.25 ms, adjustable digital filtering up to 8 ms
Resolution: 11 bit + sign bit
Inaccuracy: 1% of full scale range
 Control units of the converter 123

Analog outputs AO1 and AO2 Connector pitch 5 mm, wire size 2.5 mm2
(XAO) 0…20 mA, Rload < 500 ohm
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 mm2
(XD2D) Physical layer: RS-485
Termination by switch
RS-485 connection Connector pitch 5 mm, wire size 2.5 mm2
(X485) Physical layer: RS-485
Safe torque off connection Connector pitch 5 mm, wire size 2.5 mm2
(XSTO)
Input voltage range: -3…30 V DC
Logic levels: “0” < 5 V, “1” > 17 V
For the converter to start, both connections must be “1”
EMC (immunity) according to IEC 61326-3-1
Safe torque off output Connector pitch 5 mm, wire size 2.5 mm2
(XSTO OUT)
Control panel connection (X13) Connector: RJ-45
Cable length < 3 m
Ethernet connection Connector: RJ-45
(XETH)
SDHC memory card slot Memory card type: SDHC
(SD CARD) Maximum memory size: 4 GB
The terminals of the control unit fulfill the Protective Extra Low Voltage (PELV) requirements. The PELV
requirements of a relay output are not fulfilled if a voltage higher than 48 V is connected to the relay output.
124 Control units of the converter
 Dimension drawings 125

10
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.
126 Dimension drawings
Dimension drawings 127
 128 Dimension drawings

Transportation state without packing

Mass during transportation: 4460 kg (9833 lb)
 Cooling and heating 129

11
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

The following diagram shows how coolant circulates in the auxiliary control, grid-side
converter, LCL filter, main breaker and generator-side converter cubicles of the wind
turbine converter.
130 Cooling and heating

Coolant OUT

MBC/cap LCL Grid-side converter Generator-side converter ACU CCU

+12.5 +01.4 +01.1 +01.2 +11.1 +11.2 +01.3 +01.31

PT2

V201
B32

Grid-side Grid-side Generator Generator

converter converter -side -side
modules modules converter converter
modules modules

V101
PT1

B31

+01.5

Coolant IN

B31 = inlet coolant temperature monitoring

B32 = outlet coolant temperature monitoring
PT1 = inlet pressure sensor
PT2 = outlet pressure sensor (pressure difference is monitored, PT1-PT2, to ensure sufficient flow)
V201 = bleeding valve
V101 = draining valve
 Cooling and heating 131

Planning the cooling system

 Connection to a customer cooling unit
General requirements
Equip the system with an expansion tank to damp pressure rise due to volume changes
when the temperature varies. Keep the pressure within the limits specified in
Specifications below. Install a pressure regulator to ensure that the maximum permissible
operating pressure is not exceeded.
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 Specifications on page 139.

Coolant temperature control

The temperature of the coolant in the internal cooling circuit must be kept within the limits
specified in Specifications on page 139. Note that the minimum temperature depends on
ambient temperature and relative humidity.
The following diagram shows an example of coolant temperature control using the three-
way valve in the external cooling circuit. Part of the infeed coolant flow is directed into the
return pipe through a three-way valve without letting it circulate in the internal cooling
circuit if the coolant in the internal circuit is too cold.

TC

Return

Internal circuit External circuit

Infeed
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.
1. Ensure that there is sufficient space and free access to make proper cooling pipe
connections between the liquid cooling unit and the converter. It is not allowed to use
inflexible and fixed cooling pipe connections between two separate units (eg, liquid
cooling unit and the converter connection). Always use a flexible connector that can
reduce possible stress caused by eg, vibration.
2. Check visually that the converter liquid pipes are not damaged (threads and flange
joint not damaged).
3. Connect the external cooling circuit directly to the coupling pipes on the side of the
converter. Lay liquid piping with extreme care. Secure the pipes properly mechanically
and check for leaks. See chapter Technical data for the pipe materials.
4. Position the liquid pipe ends against each other.
5. Centre the connector onto the pipe ends.
6. Tighten the
• threaded connector carefully and ensure that it is slid on the pipe ends. The use of
appropriate sealant is recommended.
• flange bolts to a minimum torque of 70 N·m (52 lbf·ft).
7. Make sure that the liquid pipes are securely connected.
 Cooling and heating 133

Filling up and bleeding the internal cooling circuit

Both the converter and coolant must be at room temperature before filling in the cooling
circuit.

WARNING! Obey these instructions. If you ignore them, injury or death, or

damage to the equipment can occur.

• Make sure that the maximum permissible operating pressure is not exceeded.
When necessary control the pressure to appropriate level by draining excess coolant
out of the system.
• Do not drain propylene glycol into the sewer system.
• Be careful when you bleed the cooling circuit. Air bubbles in the circuit may reduce or
completely block coolant flow and cause overheating. Fill up and bleed the pumps in
the cooling circuit carefully as they can get damaged when run dry. Obey the
instructions of the external the cooling unit.

 Converters with a customer cooling unit

Notes:
• The bleed valves in the converter are used only to vent the air from the circuit so that it
can be displaced by the coolant. The actual bleeding of the circuit must be done via an
external bleed valve installed at the highest point of the 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.
• Observe the instructions given by the manufacturer of the cooling unit. Pay special
attention to filling up and bleeding the pumps properly as they may be damaged if
operated when dry.
• Draining propylene glycol into the sewer system is not allowed.
1. Open the bleed valve at the cooling unit.
2. Lead the bleed hoses into buckets or other suitable containers. Extend the standard
hoses if necessary.
3. Fill the circuit with coolant. For coolant specification, see below.
4. After the converter is filled up, coolant will start flowing from the bleed hose of the
converter. Let some coolant flow out before closing the bleed valve.
5. Let any air remaining in the system out through the bleed valve at the cooling unit.
6. Close the bleed valve at the cooling unit.
7. Continue to fill in coolant until a base pressure of 100…150 kPa is achieved.
8. Open the bleed valve of the pump to allow any air out.
9. Re-check the pressure and add coolant if necessary.
10. Start the coolant pump. Let any air remaining in the system out through the bleed
valve at the cooling unit.
11. After one to two minutes, stop the pump or block the coolant flow with a valve.
12. Re-check the pressure and add coolant if necessary.
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.
Adjustments
• Set the base pressure to 100…150 kPa by draining coolant from the fill/drain coupling.
• Control the coolant temperature so that it stays between the limits stated in
Specifications on page 139.

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.

1. Lead the bleed hose into a bucket or other suitable container. Extend the standard
hoses when necessary.
2. Open the bleed valve to let air displace the liquid.
3. If required, dry the piping with compressed oil-free air of less than 6 bar (600 kPa).
4. If the converter is to be stored in temperatures below 0 °C (32 °F),
• dry the cooling circuit with air
• fill the cooling circuit with a mixture of water and coolant according to section
Freeze protection and corrosion inhibition on page 140
• drain the cooling circuit again.

Cooling station control

The purpose of this instruction is to explain the cooling station control in general level.
Details can be found in the customer circuit diagrams and in the firmware manual of the
converter.
Cooling station is controlled by the converter. One converter type is compatible with all
four variants of cooling station:
• cold climate variant with speed-controlled cooling fans,
• cold climate variant with start/stop controlled cooling fans,
• standard climate variant with speed-controlled cooling fans,
• standard climate variant with start/stop controlled cooling fans.
The converter controls and supervises cooling station operation during:
• heating
• drying
• cooling operation phases.

 Start
At first, the auxiliary power is not switched on and the printed circuit boards are not
energized. The system is started when the auxiliary power 230 V AC (UPS) or 400 V AC
(non-UPS) is connected. The temperature of the auxiliary control cubicle is monitored by
 Cooling and heating 135

using a thermostat. If the temperature is below T1, heating of the auxiliary control cubicle
is started by using the electrical heater. Cooling unit changes to ACU heating state. The
value of temperature T1 depends on thermostat hysteresis level in use.
• Cold -> warm T1 = +15 °C (59 °F)
• Warm -> cold T1 = +5 °C (41 °F)
When temperature is above T1, there may be condensed moisture inside the converter
and the converter has two options for start:
• OnSiteMode ON: A person checks at the turbine that no condensation occurs. Dry-out
phase can be bypassed with a push button which is located in the auxiliary control
cubicle. Cooling unit control changes to Booting state.
• OnSiteMode OFF: Nobody checks at the turbine if condensation has occurred. Dry-
out phase of the auxiliary control cubicle is required to avoid possible damage due to
condensed water. Cooling unit control changes to ACU dry-out state.

 ACU heating
The auxiliary control cubicle is equipped with electrical heating elements. The auxiliary
control cubicle needs to be heated before the BCU control units can be powered. Heating
will take up to one hour.

 ACU dry-out
Electrical heating elements are used to dry out the auxiliary control cubicle. The auxiliary
control cubicle needs to be dried out before the BCU control units can be powered. It will
take one hour.

 Booting
BCU control units are powered. Converter communication as CAN slave starts. Maximum
time for booting the control units and CAN communication wake-up is one minute. The
firmware checks the re-cooling unit, see the firmware manuals for details.
Temperature in each converter cubicle is monitored separately by using thermostats. If
temperature of any cubicle is below T1, cooling unit control changes the state to Converter
heating.
If temperature in all cubicles is above T1, condensation inside the converter may have
occurred and the converter has two options for start:
• OnSiteMode ON / short black-out: A person has checked at the turbine that no
condensation occurs. Dry-out phase can be bypassed with a push button which is
located in the auxiliary control cubicle. If black-out was so short that no condensation
may have occurred, the dry-out phase is bypassed. The length of the black-out is
evaluated by using a real time clock in control units. Cooling unit control changes the
state to Run.
• OnSiteMode OFF: Converter dry-out phase required. Cooling unit control changes to
Converter dry-out state.
136 Cooling and heating

 Faulted
• The pump is stopped.
• Switch off the coolant heater.
• Switch off the fans.
• Switch off the fan heaters.
• If the fault is reset, the state will change back to Booting and the firmware checks will
start over.

 Converter heating
• Coolant pump is running.
• Coolant heaters started after parameter-based delay.
• Coolant pressure is monitored by pressure sensor. When the temperature of the main
breaker cubicle is above -20 °C (-4 °F), the fans inside the converter cabinet start and
speed up the warming process.
• The electrical heater in the auxiliary control cubicle is re-started if the temperature of
the auxiliary control cubicle drops below 5 °C (41 °F).
• The fan located on the heat exchanger of the auxiliary control cubicle is controlled by
the control unit. The purpose is to avoid re-cooling of already heated auxiliary control
cubicle. The fan is started when the measured coolant inlet temperature is above
+10 °C (50 °F).
• ABB recommends to use 15 kW heating power. Converter heating time with 15 kW
heating power is:
• -25…+15 °C (-13…59 °F): 3h 30min
• -20…+15 °C (-4…59 °F): 2h 30min
• -15…+15 °C (5…59 °F): 2h 15min
• -10…+15 °C (14…59 °F): 2h
• -5…+15 °C (23…59 °F): 1h 45min
• When all temperatures are above 15 °C (59 °F), the state will change to Run.

 Converter dry-out
As converter heating state with following exceptions:
• To dry-out the converter cabinet: 12 hours warming with converter fans running
• When the dry-out time has elapsed, the state will change to Run.

 Run
• Coolant pump will run all the time to avoid concentration of possible particles and
deterioration of gaskets.
• Coolant pressure is monitored by pressure sensor.
• Condensation is prevented by keeping the coolant temperature higher (+5 °C (41 °F))
than the ambient temperature, but never less than +15 °C (59 °F). This will override
the normal cooling level activation criteria or can activate the heaters (temperature
hysteresis limits to switch on/off heater and stopping/starting all fans).
• For details of the Run mode, see the firmware manual of the converter.
 Cooling and heating 137

 State diagram

Auxiliary power is connected to connector XD001

Start

ACU temp < T1 ACU temp > T1 AND ACU temp > T1 AND
OnSiteMode OFF OnSiteMode ON

ACU heating and dry-out

• ACU heating and dry-out using electrical heater
• HW timer for dry-out (A hours)

Temp > T1 Temp > T1

AND AND
Timer > A hours OnSiteMode ON

Hardware

Fault in recooling Software

unit
Faulted Booting
• Pump stopped • Control units booting 1 min
• Return to Booting when • Required system level healthy checks
Fault reset
reseted

Converter temp all Converter

Converter temp all < T1 > T1 and temp all > T1
OnSiteMode OFF AND
Converter heating Heating time
(OnSiteMode
depends on
• Heat converter using coolant heaters ON OR Black
used heating
• ACU electrical heater used if needed out < C hours)
power in re-
cooling unit
Fault in
recooling unit Converter temp all > 15 °C (59 °F)
Faulted

Converter dry-out B hours

Converter temp > T1 • Dry-out converter using coolant heaters
AND (HasBeenIn
RunState OR Converter Fault in recooling
OnSiteModeOn) Timer > B hours OR unit
temp < T1 OnSiteMode ON Faulted

Run
• Normal operation:
heating / cooling as needed

Fault in recooling
unit

Faulted
138 Cooling and heating

OnSiteMode push button is located in the upper part of the auxiliary control cubicle.

OnSiteMode push button

• Push ON (default OFF)

 Manual control

WARNING! Do not use manual control constantly. Use it only in special cases,
eg, when adding cooling liquid to the system. Normally, use automatic mode.

You can control the cooling station manually. To switch to manual mode, set parameter
86.71 Cooling unit control enable to Manual mode. Select the features you want to activate
with parameter 86.24 Manual control word.
To switch back to automatic control, set parameter 86.71 Cooling unit control enable to
Automatic mode.
 Cooling and heating 139

Specifications
 Temperature limits
Ambient temperature: See chapter Technical data on page 107.
Minimum coolant inlet temperature: Condensation or frost is not allowed. The minimum
coolant temperature to avoid condensation (at an atmospheric pressure of 1 bar /
100 kPa) is shown below as a function of the relative humidity (φ) and the ambient
temperature (Tair). 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).
Tair Min. Tcoolant (°C)
(°C) φ = 95% φ = 80% φ = 65% φ = 50% φ = 40%
5 4.3 1.9 -0.9 -4.5 -7.4
10 9.2 6.7 3.7 -0.1 -3.0
15 14.2 11.5 8.4 4.6 1.5
20 19.2 16.5 13.2 9.4 6.0
25 24.1 21.4 17.9 13.8 10.5
30 29.1 26.2 22.7 18.4 15.0
35 34.1 31.1 27.4 23.0 19.4
40 39.0 35.9 32.2 27.6 23.8
45 44.0 40.8 36.8 32.1 28.2
50 49.0 45.6 41.6 36.7 32.8
55 53.9 50.4 46.3 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).

Maximum coolant inlet temperature: 50 °C (122 °F) without derating of the converter
output capacity. Range above 50 °C (122 °F) is allowed as follows:
Range Converter output current derating
50 … 55 °C 2.5% per 1 °C (1.8 °F) temperature increase
(122 …131 °F)

Maximum temperature rise: 13 °C (55.4 °F); depends on mass flow.

 Pressure limits
Base pressure: 100…150 kPa (recommended); 200 kPa (maximum). Base pressure
denotes the pressure of the system compared with the atmospheric pressure when the
cooling circuit is filled with coolant.
Maximum design pressure: 500 kPa
Recommended design maximum pressure: 380 kPa. Note: Contact ABB if you need to
rise the pressure over this limit. The pressure difference must be within given limits to
avoid malfunction due to excessive coolant flow.
140 Cooling and heating

Nominal pressure difference: 110 kPa / 120 kPa (hydrostatic)

Maximum pressure difference: 170 kPa / 180 kPa (hydrostatic)

 Water quality
Tap water
The use of drinking water without gas/bubbles is allowed as follows:
• The water must fulfill the requirements of the Council Directive 98/83/EC of 3/11/98 on the quality of water
intended for human consumption.
Note: The following requirements apply to the water to be used in the coolant, not the water-glycol-inhibitor
mixture.
pH value 6.0…8.0
Chloride < 50 mg/l
Fluoride < 50 mg/l
Sulphate < 100 mg/l
Total dissolved solids < 200 mg/l, no deposits are allowed at the tempera-
ture of +57 °C (153 °F)
Total hardness as CaCO3 < 250 mg/l
Conductivity < 400 µS/cm (this equals the resistance of >
2500 ohm/cm)
The water must be clean of solid matter. The use of purified water which is not intended for
human consumption is forbidden.

 Freeze protection and corrosion inhibition

WARNING! Pay special attention to the composition of the coolant. ABB allows
only Antifrogen N type coolant, and no additional inhibitor/freeze protector must
not be used. ABB recommends 44% concentration of Antifrogen N. For other
coolants, contact your local ABB representative. THE 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.
Frost protection down to Coolant concentration Water concentration
-20 °C (-4 °F) 33% 66%
-27 °C (-16.6 °F) 40% 60%
-38 °C (-36.4 °F) 50% 50%
-54 °C (-65.2 °F) 60% 40%

WARNING! Operation at liquid temperatures below 0 °C (32 °F) is not permitted

even with antifreeze.

Liquid mixture quality

The pH level of the coolant must not be manipulated by adding chemicals not specified in
this document. This may build up sediment in the liquid.
 Cooling and heating 141

Approved coolants
• Antifrogen N. 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.

 Materials
Materials used in the internal cooling circuit are:
• stainless steel AISI 316L (UNS 31603)
• heavy gauge aluminum
• plastic materials such as PA, PEX and PTFE
Note: PVC hoses are not suitable for use with antifreeze.
• rubber gasket NBR (nitrile rubber).
Use only these materials in the external cooling circuit, too.

WARNING! When connecting external piping to the internal cooling circuit, use
only materials that are specified above. Copper and brass must not be used under
any circumstances. Even minor dissolution of copper can cause copper
precipitation on aluminum and subsequent galvanic corrosion. The liquid cooling system
may not contain any zinc (for example, galvanized pipes) at all since zinc would react with
the inhibitor.
142 Cooling and heating
—
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.

Product training
For information on ABB product training, navigate to new.abb.com/service/training.

Providing feedback on ABB Drives manuals

Your comments on our manuals are welcome. Navigate to
new.abb.com/drives/manuals-feedback-form.
abb.com/windconverters

3AXD50000028542 Rev E (EN) 2019-01-14

© Copyright 2019 ABB. All rights reserved.

Specifications subject to change without notice.