Standard documentation

The following standard documentation for the PCS6000 are on the memory stick that is supplied with the converter:

– User manual: this document

– Following appendices:

• A01: Applicable standards & conformity 

 • A02: Mechanical drawings 

 • A03: Electrical drawings 

 • A04: Operation and interface documents 

 • A05: Reports and templates 

 • A06: Data sheets for components 

 • A07: Upgrades and modifications 

 • A08: Fault handbook

Related documents

PCS6000 Service Manual 3BHS600000E80

PCS6000 preventive maintenance schedule 3BHS600000E88

PCS6000 product family water cooling unit, operations and maintenance manual 11944677 ZAE

Painting specification for ACS1000, ACS2000, ACS5000 and ACS6000/ ACS6080 3BHS104301 E01

Mechanical and electrical interface description 3BHS856856E42

Power cables engineering guideline 3BHS542290E01

Power cabling specification 3BHS856856E45

Auxiliary power and control cables guideline 3BHS813742 E01

EMC and grounding plan 3BHS856856E62

Schaltanlagen, ABB Calor Emag Taschenbuch, 10th edition

Terms and abbreviations

The following table lists terms and abbreviations you should be familiar with when using this user manual. Some of the terms and abbreviations used in this user manual are unique to ABB and might differ from the normal usage.

1CL Single Conversion Line

2CL Dual Conversion Line

BRU Braking Resistor Unit

CCA Converter Cabinet

CL Conversion Line

CCU Converter Control Unit

CT Current Transducer

DC Direct Current

DLU DC-Link Unit

EMC Electromagnetic Compatibility

ESD Electrostatic discharge

FCA Filter Cabinet

FIU Filter Unit

FRM Filter Reactor Module

GBM Grid Breaker Module

GBU Grid Breaker Unit

GDM Generator Disconnector Module

GEB Generator Breaker

GRB Grid Breaker

HEX Heat Exchanger

HFM High pass Filter Module

I/O Input / Output

IGCT Integrated Gate Commutated Thyristor

MCB Main Circuit Breaker

NCM Neutral point Connection Module

NPC Neutral Point Connection

PE Protective Earth (Protective Ground)

PICW Person in Charge of Work

POU Power Unit

PPE Personal Protective Equipment

ABB GRID BREAKER UNIT GBU72 3BHE055094R0002 / 3BHE031197R0001 / 3BHB030310R0001

Target groups and required qualification

The converter presented in this manual is part of an industrial environment where voltages are present that contain a potential hazard of electric shock and / or burn. For this reason, only personnel who have a thorough knowledge of the converter and the industrial environment and have obtained the required qualification should handle, install, operate, or maintain the converter.

The manual addresses personnel who are responsible for unpacking, transportation, installation, operation and maintenance of the converter. The personnel must carry out the below listed tasks in a manner that does not cause physical harm or danger, and ensures the safe and reliable functioning of the converter.

Handling

Personnel must be skilled and experienced in unpacking and transporting heavy equipment.

Mechanical installation

The personnel must be qualified to prepare the installation site according to the site and equipment requirements and to perform the installation accordingly.

Electrical installation

Personnel must have a sound knowledge of the relevant electrical codes and specifications covering low and medium voltage equipment, be experienced with electrical wiring principles and know the electrical symbols typically used in wiring diagrams.

Operation

The personnel include all persons who operate the converter from the local operator panel of the converter. The personnel must know the functions of the operator panel, be adequately trained for the converter, and know the driven process. Special knowledge of frequency converter technology is not required.

Maintenance

The personnel include all persons who

– Are qualified to carry out preventive and corrective maintenance on converter as described in this manual

– Are thoroughly familiar with the converter

– Have a sound knowledge of the relevant electrical codes and specifications covering low and medium voltage equipment

– Are able to assess the hazards associated with the energy sources of the converter and act correspondingly

– Know the safe shutdown and grounding procedures for the converter system

User's responsibilities

It is the responsibility of those in charge of the equipment to ensure that each person involved in the installation, operation or maintenance of the equipment has received the appropriate training and has thoroughly read and clearly understood the instructions in this manual and the relevant safety instructions.

Intended use of the equipment

Those in charge of the converter must ensure that the equipment is only used as specified in the contractual documents, operated under the conditions stipulated in the technical specifications and on the rating plate of the converter, and serviced in the intervals as specified by ABB. Use of the converter outside the scope of the specifications is not permitted. Intended equipment use also implies that only spare parts recommended and approved by ABB must be used. Unauthorized modifications and constructional changes of the converter are not permitted.

Quality certificates and applicable standards

The following certificates and conformity declarations are available with ABB:

– ISO 9001 / ISO 14001 certificates stating that ABB has implemented and maintains a management system which fulfills the requirements of the normative standards

– CE declaration of conformity

– EMC Test Certificate PCS6000 Montena_16602

– List of standards that the converter complies with (see “A01: Applicable standards & conformity”)

Tools

 ABB offers various tool sets containing all necessary tools and equipment for installation, 

commissioning and maintenance of the converter. The content of the tool sets is described 

in the “PCS6000 Service Manual”, 3BHS600000 E80

Product description

The following sections provide information on the individual units of the PCS6000 product platform.

Field of application

The PCS6000 is a medium voltage frequency converter that has been designed for large wind turbines and tidal applications. The PCS6000 belongs to a new generation of “Full Size Power Converters”.

Converter configuration

The PCS6000 is a modular type of frequency converter that is ideal for highly demanding medium voltage applications. The design allows maximum flexibility at different power ratings and also customized solutions involving a minimum prototyping and engineering effort. Two main concepts are available:– 1CL configuration: Single conversion line– 2CL configuration: Dual conversion line that allows you to operate the system in “constricted mode”, ie, with only one conversion line, if a component fails. This mode increases the availability of the wind turbine.

The PCS6000 fits in confined spaces and its modular design enables back-to-back, face-to face, and in-line configurations.

 POU Power unit (POU)

A POU contains three 3-level NPC phase legs with IGCTs. The semiconductors are clamped into one stack. A POU is controlled and supervised by the main circuit interface board that contains the control switching machine and the measurement interface.

DC-link unit (DLU)

The DC link unit (DLU) contains the following sub assemblies:

– Neutral point connection module

– Pre-charging module

– Voltage limiting module

– dv/dt filter

– DC link grounding isolator

– Generator disconnector module

Neutralpoint connection module (NCM)

PCS6000 converter's neutral point NP is connected to earth through an RC combination to limit the dv/dt of the converter against earth. This allows the converter to operate with a single earth fault for limited period of time. Normally, an earth fault is detected and the converter switched off immediately. A second function of the NCM is to discharge the DC-Link via high resistance in the case that the VLM does not work properly.

Voltage limiting module (VLM)

The VLM has an IGCT stack. If the DC-Link voltage exceeds a certain limit, the VLM closes the current path through the braking resistor to dissipate excessive energy. Another function is discharging DC-Link during shut down of converter.

dv/dt filter module (VFM)

The VFM reduces the dv/dt on the transformer or generator winding created by switching of the IGCTs and to attenuate high frequency oscillations between the IGCT power stack and the transformer.

DC-link grounding isolator

The main function of the DC-Link grounding isolator is to ground and short-circuit the converter DC-Link in case of service or maintenance work. The DC-Link grounding isolator is blocked in open position at DC-Link voltages higher than 50 V. The handle can be locked with a padlock in closed position to prevent unauthorized operation. The 2CL converter has two DC-Link grounding isolators, one per conversion line. The DC-Link ground isolator is a two position switch.– Open position:  DC-Link is not grounded – Closed position:  DC-Link is shorted and grounded

Generator disconnector module (GDM)

Typically the GDM is installed in a DLU. The GDM has a motorized 3-phase disconnector.– Closed position:  generator is connected to the converter – Open position:  generator is disconnected – Ground position:  generator is grounded In case that the motor mechanism fails (eg, due to lost auxiliary power for the GDM), an extension spin rod can be used to operate the GDM manually. This rod is stored inside the unit.

Grid breaker unit (GBU)

The GBU is a circuit breaker on the grid side of the converter. It performs not only the usual functions of making, breaking and short circuit breaking, but also contains a three position-switch for disconnecting and grounding the grid-side cables. The circuit breaker and the three position switch are located on a common mounting plate. The three-position-switch prepares - under zero current - for the connection to earth. Grounding is established by closing the circuit breaker with the three-position-switch set to ground position. The GBM is placed in a GBU. The switch can only be operated manually by a set of hand cranks.

ABB GRID BREAKER UNIT GBU72 3BHE055094R0002 / 3BHE031197R0001 / 3BHB030310R0001

Water cooling unit (WCU)

The main tasks of the WCU are:– Ensuring constant water pressure, flow and temperature– Interfacing to the external heat exchanger equipment– De-aeration of cooling water circuit– De-ionizing the cooling water A soft starter for the cooling pumps is available as option. The WCU can be specified for connection of the external heat exchanger on the top (standard) or bottom. The WCU varies depending on the converter size.

Filter unit (FIU)

The FIU is an RLC filter tuned to fulfill the harmonic limits defined by the relevant grid standards.

Braking resistor unit (BRU)

The braking resistor is able to dissipate the full generator power (plus temporary overproduction and DC-Link discharge) in any operating condition for a certain time. The power switching to the braking resistor is done by a Voltage Limiting Module (VLM). The braking resistor is modular for different converter power ranges. The BRU can be placed somewhere close to the converter. A roof installation is possible. The maximum cable length between converter and BRU is 10 m. The monitoring/control of the BRU resistor temperature is done with a temperature model on the main circuit interface. The BRU varies depending on converter size and application.

BRU51 2 × 7.5MJ 2x1.8 Ohm / stand-alone / cable clamp DI 28 mm

BRU52 2 × 7.5MJ 2x1.8 Ohm / roof mounting / cable clamp DI 40 mm

BRU72 2 × 15MJ 2x1.5 Ohm / stand-alone / cable clamp DI 28 mm

Converter control unit (CCU)

The CCU incorporates the hardware for the control, monitoring and protection functions of the converter as well as the communication interfaces to the remote control hardware.

Cabinet design

The cabinet has been designed using the modular cabinet system of ABB and fulls the requirements of international standards. The design consists of a skeletal frame made of galvanized steel where the outer panels made of 1.5 mm thick painted galvanized steel are bolted to. Corrosion resistant materials are used to ensure durability of the cabinets.

Electromagnetic compatibility (EMC)

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

Degree of protection The standard cabinets are rated for IP 54. The sound pressure level is < 75 dB (A). Painting The standard color for the cabinets is RAL 7035 (light gray), which is applied as a powder coat paint.

Transportation

Small converters are shipped as one unit. Larger converters are shipped in separate transport units. All transport units are fitted with lifting lugs for a crane that must be used to position the units.

Safety labels

Safety labels are attached to the converter doors to alert personnel of potential hazards when working on the converter.

The standard language of the labels is English; however, other languages can be ordered. The label design is based on the relevant ANSI and ISO standards (see section 2.3, Product safety labels, page 20).

ABB PCS6000 PRODUCT FAMLIY 

ABB GRID BREAKER UNIT GBU72 3BHE055094R0002 / 3BHE031197R0001 / ABB 3BHB030310R0001

ABB 3BHE055094R0002 GBU72   

ABB 4045L0006 

ABB 3BHB006338R0002 

ABB SDCS-COM-81 3ADT220134R0001 

ABB 3AXD50000949168

ABB 3AUA0000145150  

ABB SPDSI13