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ABB PCS6000 User Manual
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ABB PCS6000 User Manual

ABB PCS6000 User Manual

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SYSTEM DRIVES
PCS6000
User manual
OWNING ORGANIZATION
ABB Switzerland Ltd.
DOCUMENT KIND
User manual
© Copyright 2012 ABB All rights reserved.
DATE
STATUS
2022-03-22
Approved
DOCUMENT ID.
3BHS600000 E40
SECURITY LEVEL
Public
REV.
LANG.
PAGE
G
en
1/114

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Summary of Contents for ABB PCS6000

  • Page 1 — SYSTEM DRIVES PCS6000 User manual OWNING ORGANIZATION DATE STATUS SECURITY LEVEL ABB Switzerland Ltd. 2022-03-22 Approved Public DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE User manual 3BHS600000 E40 1/114 © Copyright 2012 ABB All rights reserved.
  • Page 2 This document contains information about one or more ABB products and may include a description of or a reference to one or more standards that are relevant to the ABB products. The presence of any such description of a standard or reference to a standard is not a representation that all of the ABB products referenced in this document include all the features of the described or referenced standard.

  • Page 3: Table Of Contents

    Water cooling unit (WCU) ................ 37 3.2.5. Filter unit (FIU) ..................38 3.2.6. Braking resistor unit (BRU) ..............39 3.2.7. Converter control unit (CCU) ..............40 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 3/114...
  • Page 4 6.4. Cable requirements ................... 69 6.4.1. Power cables .................... 69 6.4.1.1. Recommended cable types ............70 6.4.1.2. Power Cable Dimensions............... 70 6.4.1.3. Cable Shielding, routing and separate earth wires ....................71 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 4/114...
  • Page 5 User interfaces and diagnostics ............. 98 8.4. Operating states and sequences ..............98 8.5. Anti-dew startup sequence ................99 8.6. Starting the PCS6000 converter ..............101 8.6.1. Checks before starting ................. 101 8.7. Lockout/Tagout ..................... 103 8.8. EMERGENCY OFF button ................103 8.9.
  • Page 6 Log book ....................110 10.3. Standard procedure for troubleshooting ............. 110 10.4. Alarms and faults ..................... 111 10.4.1. Fault levels ....................111 10.4.2. Alarm and fault messages..............111 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 6/114...
  • Page 7 Figure 4–1 Type and dimensions of wood pallet ............44 Figure 4–2 Roof beam placement ................. 49 Figure 4–3 Packing overview ..................52 Figure 4–4 Loading and unloading in-line PCS6000 with suspension beam ..........................55 Figure 4–5 Typical lifting with fork lift truck (top: In-line layout / bottom: back-to-back layout) ..................
  • Page 8 Figure 8–3 DC-link grounding switch in position “not grounded”, LED indication........................102 Figure 8–4 Releasing EMERGENCY OFF button ............103 Figure 8–5 Key switch ....................104 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 8/114...
  • Page 9 Table 8–1 Local control binary indications (controller output signals .......... 98 Table 8–2 Local control binary commands (controller input signals) .......... 98 Table 8–3 Local control commissioning ports ..................98 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 9/114...

  • Page 11: Introduction, Terms, Trademarks And Related Documents

    (eg, layout drawings, wiring diagrams, technical data, engineering notes). If information is required beyond the instructions in this manual, refer the matter to ABB. 1.2. Overview This manual covers the standard PCS6000 equipment and provides generic information.

  • Page 12: Contents Of This Manual

    – chapter 3, Product description, page 29 provides an introduction about the modular concept of the PCS6000 as well as a functional description of the main power components and the related control and protection devices.

  • Page 13: Standard Documentation

    INTRODUCTION, TERMS, TRADEMARKS AND RELATED DOCUMENTS 1.4. 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 •...

  • Page 14: 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. Table 1–1 Terms and abbreviations...

  • Page 15: Target Groups And Required Qualification

    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. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 15/114...

  • Page 16: Maintenance

    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.

  • Page 17: Quality Certificates And Applicable Standards

    1.10. 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 –...

  • Page 18: Tools

    INTRODUCTION, TERMS, TRADEMARKS AND RELATED DOCUMENTS 1.11. Tools ABB offers various tool sets containing all necessary tools and equipment for installation, commissioning and maintenance of the converter. The content of the tool sets is described in the “PCS6000 Service Manual”, 3BHS600000 E80.

  • Page 19: Important Safety Information

    Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE Is used to address practices not related to physical injury, but which can result in equipment damage. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 19/114...

  • Page 20: Product Safety Labels

    The pacemaker sign should be installed at the entrance to the converter room or at a minimum distance of 6 m from the converter to stop personnel with pacemakers approaching the converter. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 20/114...

  • Page 21: General Safety Instructions

    7) In case of fire in the converter room: • Observe the established rules and regulations for fire safety • Only allow firefighters with the appropriate PPE to enter the converter room PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 21/114...

  • Page 22: The 7 Steps That Save Lives

    IMPORTANT SAFETY INFORMATION 2.5. The 7 steps that save lives ABB’s 7 steps that save lives concept is a series of actions that must take place prior to commencing work on or near electrical installations. 1) Prepare for the work: do an on-site risk assessment or job hazard analysis that considers the limits of approach for shock and arc-flash.
  • Page 23 Check the earths are properly applied • Answer specific questions from the working group • Ensure the work can proceed without danger • Complete and verify the “Permit to Work” PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 23/114...

  • Page 24: Possible Residual Risks

    Wrong parameter settings • Software errors • Faulty hardware • Hazardous substances can be emitted from converter system components, eg, due to Incorrect disposal of components PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 24/114...
  • Page 25 – Operation time in constricted mode and idling with open disconnector must be reduced as far as possible PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 25/114...

  • Page 26: Important Note - Main Circuit Breaker

    – Fused contactors or motor control centers Dedicated protection relay – Transformer or converter primary cable protection – Transformer protection – Transformer secondary cable protection – Backing up the converter protection PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 26/114...

  • Page 27: Safety And Protection Requirements

    – Maximum safety trip time: 500 ms The maximum safety trip time is the maximum allowed time to ensure safe disconnection of the main power supply to prevent any hazard to personnel. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 27/114...

  • Page 28: Maintenance Recommendation

    5) Maximum protection trip time 6) Maximum safety trip time In order to meet the stipulated safety requirements, ABB recommends one of the following: – MCB is equipped with 2 independent opening coils – MCB is equipped with an opening coil and an undervoltage coil for monitoring of the control voltage –...

  • Page 29: Product Description

    3.1. 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”. 3.2. Converter configuration The PCS6000 is a modular type of frequency converter that is ideal for highly demanding medium voltage applications.

  • Page 30: Figure 3-2 Pcs6000 Configuration Examples

    PRODUCT DESCRIPTION Figure 3–2 PCS6000 configuration examples 1) Inline 1CL 2) Back-to-back 2CL Figure 3–3 PCS6000 configuration example 1) CCU (Converter control unit) 4) GBU (Grid breaker unit) 2) FIU (Filter unit) 5) DLU (DC-Link unit) 3) POU (Power unit)

  • Page 31: Pou Power Unit (Pou)

    A POU is controlled and supervised by the main circuit interface board that contains the control switching machine and the measurement interface. Figure 3–4 POU 1) Cooling pipe 3) Control 2) DC-link capacitors 4) Auxiliary supply PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 31/114...

  • Page 32: Dc-Link Unit (Dlu)

    – Generator disconnector module Figure 3–5 DLU 1) Generator disconnector module 4) Neutralpoint connection module 2) dv/dt filter module 5) Voltage limiting module 3) DC-link grounding isolator PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 32/114...

  • Page 33: Neutralpoint Connection Module (Ncm)

    PRODUCT DESCRIPTION 3.2.2.1. 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.

  • Page 34: Dv/Dt Filter Module (Vfm)

    – Closed position: DC-Link is shorted and grounded Figure 3–9 DC-link grounding isolator 1) DC-link 3) DC-link grounding isolator 2) Grounding isolator 4) Grounding isolator unlocked PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 34/114...

  • Page 35: Generator Disconnector Module (Gdm)

    If you need to operate the GDM manually, be aware to turn the GDM in the correct direction. A sticker shows the rotation direction. Figure 3–10 GDM 1) Extension spin rod 2) Rotation direction indication PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 35/114...

  • Page 36: Grid Breaker Unit (Gbu)

    3-position 5) Hand crank for disconnector switch 3) Hand crank for earthing switch 3.2.3.1. dv/dt filter module See section 3.2.2.3, dv/dt filter module (VFM), page 34. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 36/114...

  • Page 37: Water Cooling Unit (Wcu)

    5) Interface box to control 2) Expansion vessel (optional) 6) Ion exchanger vessel 3) Cooling water pump 1 7) Cooling water pump 2 (optional) 4) Outlet to re-cooler on top PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 37/114...

  • Page 38: Filter Unit (Fiu)

    Figure 3–14 Typical HFM and FRM implemented in FIU 1) Converter 4) Filter unit 2) Transformer 5) RLC filter 3) Highpass filter module (HFM) 6) Filter reactor module (FRM) PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 38/114...

  • Page 39: Braking Resistor Unit (Bru)

    2x1.8 Ohm / roof mounting / cable clamp DI 40 mm BRU72 2 × 15MJ 2x1.5 Ohm / stand-alone / cable clamp DI 28 mm Figure 3–15 Typical BRU PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 39/114...

  • Page 40: Converter Control Unit (Ccu)

    4) CT and VT interfaces 10) Local control equipment (see Fig. 8–1) 5) Mini circuit breakers (230 V AC) 11) 24 VDC backup battery 6) Slow I/O PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 40/114...

  • Page 41: Cabinet Design

    PRODUCT DESCRIPTION 3.3. 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.
  • Page 42 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). PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 42/114...

  • Page 43: Transportation, Storage And Disposal

    ▶ Transport equipment is to be chosen according to all relevant specifications and prescriptions. 4.2. Transportation The following instructions are to be observed for the transport of PCS6000 converters. The following packing options are available for the PCS6000: – Foil wrapped and wood pallet: Packing for land transportation, page 44 –...

  • Page 44: Packing For Land Transportation

    TRANSPORTATION, STORAGE AND DISPOSAL 4.2.1. Packing for land transportation This section describes how to pack a PCS6000 with foil and wood pallets for land transportation. 4.2.1.1. Wood pallet requirements The wood pallets must fulfill the following requirements: – Designed for transport by forklift –...

  • Page 45: Preparing The Wood Pallet

    NOTICE Ensure that the edge protectors are under the slings. 3. Lift the converter cabinet with the crane and lower it onto the pallet. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 45/114...

  • Page 46: Applying The Foil Barrier

    NOTE – Start at the back of the converter and continue to the front. 2. Apply tape to the vertical edge of the overlap where the 2 ends of the film meets. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 46/114...
  • Page 47 5. Fold the film down on the front and back sides of the cabinet and attach the film horizontally with tape. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 47/114...

  • Page 48: Wrapping

    3. When the machine starts to wrap the cabinet from top to bottom, increase the film tension to 35-38 units until this part of the wrapping process is complete. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 48/114...

  • Page 49: Securing Cabinets To The Pallet

    2. Secure the converter cabinet to the pallet by running band strapping through the base of the pallet and over the beams on the cabinet roof. 3. Wrap the strapping buckles with bubble wrap and ABB tape. PRODUCT DOCUMENT KIND DOCUMENT ID.
  • Page 50 3. At each end of a strap, make a 10 cm loop, thread the loop through the center of a buckle and around one the buckle legs before tightening with a tensioner. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 50/114...

  • Page 51: Packing For Sea Transportation

    Desiccants according to DIN 55474, shall be distributed inside the packed device. 4.2.2.4. Humidity indicator If desiccant with a barrier film is used for packaging, ABB recommends using a humidity indicator for a storage period of more than 12 months.

  • Page 52: Figure 4-3 Packing Overview

    3) Fixation of the converter component 7) Inspection hole for controlling the indicator against sliding Ethafoam pad 8) Humidity indicator 4) Plastic compound cushioning PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 52/114...

  • Page 53: Packing Symbols

    4.2.3. Packing symbols The packaging is labeled with all relevant symbols and instructions for handling and storing PCS6000 according to DIN 55402-1, and DIN 55474. Fragile, handle with care Contents of the transport package are fragile therefore it shall be handled with care.

  • Page 54: Loading And Unloading

    – Loading area is to be checked on leakage and cleanliness – ABB will not accept any liability unless the damage is properly reported. Use damage description report at the end of the chapter. – In order to avoid damage to the equipment do not remove the packing before moving the equipment to the place of installation.

  • Page 55: Loading And Unloading By Crane

    – Adjust the length of the hanger to provide a straight lifting position. – In order to avoid any buckling of the transport frame and damage of the PCS6000 due to excessive pressure, the maximum angle between the hanger and the vertical line (base frame) may not exceed 30°.

  • Page 56: Loading And Unloading By Fork Lift Truck

    ▶ Length and entry width must have dimensions ensuring a safe transport (see center of gravity marking on the packing) 4.2.6.1. Fork lift truck requirements For loading and transporting the PCS6000 cabinets a fork lift truck is to be used that fulfills the following criteria: – Load capacity –...

  • Page 57: Unpacking

    4.2.7. Unpacking NOTICE Risk of component damage! Dust inside the PCS6000 can reduce the creepage distances and increase the thermal stress. ▶ Only unpack the PCS6000 in a clean and dust-free area ▶ Always cover the equipment with plastic sheets and carefully remove when construction work occurs near the converter ▶...

  • Page 58: Figure 4-6 Unpacking The Equipment

    3) Side wall 5. Check the condition of any accompanying equipment. 6. Compare the complete delivery with the purchase order. IMPORTANT! If parts are missing, contact immediately the shipping company and the local ABB service organization. PRODUCT DOCUMENT KIND DOCUMENT ID.

  • Page 59: Unpacking Additional Parts

    – Crane (recommended) – Fork lift truck IMPORTANT! The equipment must always be placed on a level surface. Make sure that the equipment cannot topple while being moved. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 59/114...

  • Page 60: Moving By Crane

    – Always use a suspension beam for lifting as shown in Fig. 4–7. Ropes of insufficient strength and length are not allowed when lifting the equipment by crane. Figure 4–7 Moving PCS6000 with suspension beam 1) Hook 5) Eyebolt 2) Lifting cables...

  • Page 61: Moving By Transport Rolls

    When moving the equipment on the floor the following must be assured: – Use transport rolls – Wood pallet must be removed when using transport rolls Figure 4–8 Moving PCS6000 by transport rolls 1) Cabinet 3) Eyebolt 2) Base frame 4.2.8.3.

  • Page 62: Transport Conditions

    4.3.1. Storage conditions The PCS6000 converter can be stored for up to 1 year in the original packaging as long as it is not damaged or opened. NOTE – For information on longer storage periods contact ABB.

  • Page 63: Storage And Handling Of Spare Parts

    4.4. Disassembly and disposal of equipment Dispose of the following components according to local regulations: – Batteries – Capacitors – Printed circuit boards – Electronic components PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 63/114...

  • Page 65: Mechanical Installation

    NOTICE Keep dust-free! Dust inside the PCS6000 can reduce the creepage distances and increase the thermal stress. ▶ Always unpack the PCS6000 in a clean and dust-free surrounding area. Furthermore, no dust and dirt producing work may be accomplished in this area during the installation as long as the doors and cable covers are open.

  • Page 66: Cabinet Mounting Instructions

    Metallic dust in particular may cause serious damage and lead to malfunction when the PCS6000 is powered up. ▶ When mounting the PCS6000 ensure that no dirt enters. Recommended order of the mounting process: 1. Drill the mounting holes in the floor 2.

  • Page 67: Electrical Installation

    The installation includes the following items: – Electrical installation instruction of MV connection, page 76 – Grounding the converter system, page 80 – Auxiliary connection, page 84 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 67/114...

  • Page 68: Emc Concept

    IEC 61800-3 proposes to subdivide the installation into different EMC zones. Fig. 6–1 shows the generic EMC zone concept according to this standard. The PCS6000 converter system is designed in accordance with IEC 61800-3. The applicable zones are – Zone 0: power supply (high voltage network) –...

  • Page 69: Cable Requirements

    Power, auxiliary and control cables have different requirements. 6.4.1. Power cables For information on the requirements for power cables, ground cable and equipotential bonding conductor, see: – “Power cables engineering guideline”, 3BHS542290 E01 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 69/114...

  • Page 70: Recommended Cable Types

    (method of installation, voltage drop due to cable length etc.) and local regulations must be considered. Refer also to the specifications supplied by the power cable manufacturer. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 70/114...

  • Page 71: Cable Shielding, Routing And Separate Earth Wires

    6 / 10 IEEE: 5 / 8 kV Rating factor 0.85 To cover converter operation Maximum length Surge phase current including 16.2 kArms Maximum 500 ms DC offset PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 71/114...

  • Page 72: Generator Side (Converter - Generator)

    IEEE: 5 / 8 kV Rating factor 0.85 To cover converter operation Maximum length NOTE – In some cases, the braking resistor cables are included in the converter delivery. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 72/114...

  • Page 73: Auxiliary And Control Cables

    Synchronization cables are used in drives with an ARU. A shielded, 3-phase cable without neutral wire is required for the supply voltage of the synchronization transformer. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 73/114...

  • Page 74: Installation Rules For Busbars, Cabling And Wiring

    (PEC: Parallel Earth Conductor, e.g. grounded cable duct or grounded cabinet). If the installation length of the cables differs, the distance can be linearly adapted. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 74/114...

  • Page 75: Summary

    Cable for relay contacts On both sides Cable duct along grounded metal parts Lighting, motor starter, heating On both sides Cable duct along units grounded metal parts PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 75/114...

  • Page 76: Electrical Installation Instruction Of Mv Connection

    – Type of connector, eg, straight, P3SC, no. 305 015 – Coding: AF01 – Cable cross section, eg, 240 mm – Outer diameter of inner mantle, eg, 28 mm PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 76/114...

  • Page 77: Types Of Pfisterer® Plug Connectors

    – Number: 305 322 - AF01 – Nominal current: 800 A – Cable cross section: 70 to 240 mm Figure 6–5 Details of the Pfisterer® PLUG elbow connector for 1 cable PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 77/114...

  • Page 78: Pfisterer® Plug Connector Details (P3Sc)

    10) Housing nut 4) Gasket 11) Pressure washer 5) Free area - approximately 10 mm 12) Internal mantle 6) Assembled lug 13) Screen weave 7) Screen weave braid PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 78/114...

  • Page 79: Cable Connection Systems

    Figure 6–8 DLU and GBU rear cable connections (A) and rear cable entry (B) Figure 6–9 DLU and GBU top cable connections (A) and top cable entry (B) PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 79/114...

  • Page 80: Grounding The Converter System

    According to “Schaltanlagen, ABB Calor Emag Taschenbuch, 10th edition”, chapter 5.3.3, the minimum cross-section of a ground conductor should be defined as follows: -------- - ...

  • Page 81: Converter Grounding

    External grounding cables must be connected from the main ground (PE) of the installation to the converter. Figure 6–10 Grounding cam at a base frame with M12 bolt Figure 6–11 Ground rail for cable shield connections PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 81/114...

  • Page 82: Figure 6-12 Grounding The Grid Side (A) And Generator Side (B) Of A

    6) Ground cable 2) System ground 7) Grid side converter 3) Cable shield 8) Generator side converter 4) Cable armor 9) Generator 5) Equipotential bonding conductor PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 82/114...

  • Page 83: Figure 6-13 Grounding The Generator Side Of The Converter System Of A 2Cl Converter System

    6) Ground cable 2) System ground 7) Grid side converter 3) Cable shield 8) Generator side converter 4) Cable armor 9) Generator 5) Equipotential bonding conductor PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 83/114...

  • Page 84: Auxiliary Connection

    CCA and FCA. One potential manufacturer of matching cable entry systems is: – Phoenix contact – Product: cable entry system – Frame size: B24 PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 84/114...

  • Page 85: Auxiliary Power Supply Connection

    Figure 6–14 Position of the auxiliary power terminals inside the CCU 1) Auxiliary power UPS 3) Auxiliary power 3AC400V without UPS 2) Auxiliary power without UPS 4) Auxiliary power 3AC400V with UPS PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 85/114...

  • Page 86: Figure 6-15 Position Of The Cutouts For Cable Entry Into The Ccu

    Auxiliary cable entry, page 84. Figure 6–15 Position of the cutouts for cable entry into the CCU 1) 3AC400V auxiliary entry/MCTs 24 pole 2) MCTs 24 pole cutout cutout PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 86/114...

  • Page 87: Control Cable Connection

    (eg, glands) must be provided by the customer. All control cables have to be connected inside the CCU. Figure 6–16 Position of the control cable terminals inside the CCU 1) Current and voltage transducers 2) Control signals PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 87/114...
  • Page 88 ELECTRICAL INSTALLATION PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 88/114...

  • Page 89: Commissioning

    7. Commissioning 7.1. Required qualification Commissioning, parameter adjustments and functional tests must be carried out only by qualified commissioning personnel that have been certified by ABB. 7.2. Commissioning procedure Information on the commissioning procedure and the start conditions for commissioning can be obtained from ABB.

  • Page 90: Commissioning Checklists

    6) Visual inspection: • No badly affixed or damaged components • No foreign objects left in the cabinet • No dirt, dust or moisture in the cabinet PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 90/114...

  • Page 91: Electrical Installation Checklist

    1) Types and cross sections of control cables suitable for the signal type and signal level.  2) Types and cross sections of power cables selected according to the ABB power cable specification.  3) Cable entries are prepared according to the instructions in this user manual (3BHS600000 E40).

  • Page 92: Main Circuit Breaker (Mcb) Checklist

    6) Local operation of MCB is disabled.  7) Emergency-off loop is tested.  7.6.4. Input transformer checklist  1) Transformer is selected and installed according ABB Specification.  2) Grounding is completed.  3) Transformer auxiliaries (eg, dehydrating breathers, cooling, protection devices) are ready.

  • Page 93: Insulation Test Checklist

    Mechanical and electrical interface description • Control interface description • Communication link specification • Transformer specification • Electrical circuit diagram • Grid breaker specification • External cooling circuit requirements PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 93/114...

  • Page 95: Operation

    8.1. Operation conditions As soon as the converter is unpacked, the environmental conditions for operation apply. Between unpacking and first operation of the PCS6000 converter ABB suggests to take the following precautions: – Weekly visual check of the PCS6000 converter –...

  • Page 96: Safety

    Risk of component damage. Running the PCS6000 with incorrect data can result in improper operation, reduction in control accuracy and damage to equipment. ▶ PCS6000 parameters are set during commissioning of the device and must not be changed afterwards. PRODUCT DOCUMENT KIND DOCUMENT ID.

  • Page 97: Control Interfaces And Local Control Equipment

    7) EMERGENCY OFF function 8) Commissioning ports 3) Lockout/Tagout interlocking keys 9) Generator side voltage free 4) Grid side voltage free 10) Generator grounded 5) Grid grounded PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 97/114...

  • Page 98: User Interfaces And Diagnostics

    8.4. Operating states and sequences See “Appendix A04 Operation & Interface Documents, Control Interface and Operation Description” for detailed information on the control system and interfaces. PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 98/114...

  • Page 99: Anti-Dew Startup Sequence

    OPERATION 8.5. Anti-dew startup sequence The PCS6000 converter can be operated at very cold temperatures. The medium voltage power part of the converter can work, if the following conditions are fulfilled: Start and operating criteria for the power part: 1) The cooling water temperature is > 0°C (water/glycol mixture).

  • Page 100: Figure 8-2 Flow Chart Of Anti-Dew Startup Sequence (Pf2)

    Converter will now start-up completely and enters the Converter is pump ON converter OFF-mode state. ready for start-up Figure 8–2 Flow chart of anti-dew startup sequence (PF2) PRODUCT DOCUMENT KIND DOCUMENT ID. REV. LANG. PAGE PCS6000 User manual 3BHS600000 E40 100/114...

  • Page 101: Starting The Pcs6000 Converter

    OPERATION 8.6. Starting the PCS6000 converter The PCS6000 can only be taken into operation after it has been properly installed and commissioned. 8.6.1. Checks before starting IMPORTANT! Before commissioning and first start-up proceed according to chapter 7, Commissioning, page 89.

  • Page 102: Figure 8-3 Dc-Link Grounding Switch In Position "Not Grounded", Led Indication

    IMPORTANT! Grid disconnectors and grid grounding isolators are not operated by the PCS6000 control. 11. Check that the main circuit breaker is in operating position. The PCS6000 is now in status OFF and ready to be started via the customer's HMI system. PRODUCT DOCUMENT KIND DOCUMENT ID.

  • Page 103: Lockout/Tagout

    The PCS6000 contains no user-operable parts inside the medium voltage cabinets. Access to these units is permitted for qualified service personnel only. ▶ De-energize before lockout/tagout! Before the internals of the PCS6000 are accessed for service purposes, the relevant components of the converter must be de-energized safely.

  • Page 104: Key Switch

    Two protection levels are used in the PCS6000: – Alarm: does not shut down the PCS6000. A start is possible. – Fault: always shuts down the PCS6000 by means of a trip. The start is prevented. 8.10.1. Alarm and trip reset Press the ACKNOWLEDGE ALARM or ACKNOWLEDGE TRIP function key or select the appropriate command from remote control to reset all pending alarms and trips.

  • Page 105: Preventive Maintenance

    ▶ Always use proper tools and equipment which are certified for medium voltage applications. ▶ After switching off the PCS6000 frequency converter, there is still voltage on the auxiliary energy distributor of the converter control system. ▶ There can also be external auxiliary and control voltages (eg, of measuring circuits) even if the internal auxiliary power supply is switched off.

  • Page 106: General Directives

    Observing the maintenance schedule can prevent system malfunctions. ABB is not liable for defects as a result of neglecting preventive maintenance work. ▶ All repair work must be carried out by trained personnel according to the ABB service and authorization concept.

  • Page 107: Performance

    (see section 9.3.3, Performance, page 107). 9.3.5. Maintenance schedule Carry out all maintenance tasks according to the preventive maintenance schedule and the applicable service instructions, on time and at the stated intervals in the “PCS6000 preventive maintenance schedule”, 3BHS600000 E88. PRODUCT DOCUMENT KIND DOCUMENT ID.

  • Page 109: Troubleshooting

    TROUBLESHOOTING 10. Troubleshooting The following sections provide instructions on how to proceed when encountering a problem with the PCS6000. It is addressed to qualified personnel who are responsible for servicing the PCS6000. 10.1. Safety Before you begin, read and understand the general safety instructions in chapter 2, Important safety information, page 19.

  • Page 110: General Directives

    Observing the maintenance schedule can prevent system malfunctions. ABB is not liable for defects as a result of neglecting preventive maintenance work. ▶ Any repair work must be carried out by trained personnel according to the ABB service and authorization concept.

  • Page 111: Alarms And Faults

    5. If the fault is cleared, send the Acknowledge command via the remote interface to reset all alarms. The PCS6000 can only be reset if all faults are eliminated. After a reset the PCS6000 goes into OFF mode and is ready to be restarted.
  • Page 114 /114 — ABB Switzerland Ltd. Bruggerstrasse 66 CH-5400 Baden Switzerland new.abb.com/power-converters-inverters/wind-turbines — © Copyright 2012 ABB. All rights reserved. The information in this document is subject to change without notice.

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