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TECHNICAL REPORT
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Title: MAINTENANCE MANUAL CONVERTER CABINET G8X DTC
INDEX
1 Aim
2 Scope
3 Definitions and acronyms
4 Applicable documents
5 Maintenance operations
5.1 Safety rules
5.2 Power cabinet maintenance (busbars+protections)
5.3 Converter cabinet maintenance
5.4 FG008 circuit braker maintenance
6 Overview of the converter cabinet and components
6.1 FG008 Cabinet
6.2 FF005 Cabinet
6.3 FG002 Cabinet
6.4 Control cabinet (sliding frame)
6.5 Power modules cabinet
6.6 Inverter module (ISU/INU)
7 Annexes
7.1 Pictures
7.2 Drawings
7.3 References
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Title: MAINTENANCE MANUAL CONVERTER CABINET G8X DTC
1 AIM
This document explains the maintenance operations to be made onto the converter cabinets
(busbar+converter) with DTC technology for G8x wind generators.
2 SCOPE
This document is aimed to people in charge of the maintenance of the converter cabinet
(busbar+converter), made by ABB Finland, in all the G8x DTC machines.
Cabinet codes are:
• GP010927: Converter cabinet G8x DTC 50Hz HT
• GP009049: Converter cabinet G8x DTC 60Hz HT
• GP010928: Converter cabinet G8x DTC 60Hz LT
• GP031717: Converter cabinet V2 G8x DTC 50Hz HT
• GP031718: Converter cabinet V2 G8x DTC 60Hz HT+LT
3 DEFINITIONS AND ACRONYMS
• DTC: Direct Torque Control. ABB´s name for generator´s control algorithms of
converter
• HT: High temperature
• LT: Low temperature.
4 APPLICABLE DOCUMENTS
These maintenance operations are based on the information supplied by ABB in the following
documents:
• ACS800-67 Wind Turbine Drives for Asynchronous Slip Ring Generators. Hardware
manual. ABB´s ref.: 3AFE68392554
• G80 Power Cabinet. Suplement to ACS800-67 Hardware Manual. ABB´s ref.:
3AFE68583161
• Installation, service and maintenance instructions for low voltage air circuit-breaker SACE
Emax. ABB´s ref.: ITSCB 601933/001
• All these manuals are included in the updated manual “Supplement to ACS800-67
Hardware Manual_Rev B”. For detailed description of each operation, please refer to
this document.
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Title: MAINTENANCE MANUAL CONVERTER CABINET G8X DTC
5 MAINTENANCE OPERATIONS
5.1 SAFETY RULES
• See “Safety instructions” paragraphs in the manuals.
• Only a qualified electrician is allowed to perform the maintenance.
• FG008, FG002 ad FF005 must be open. Medium voltage switchgear must be open. The
rotor of the generator must be locked with a mechanical brake.
• Wait for 5 minutes to let the intermediate circuit capacitors discharge.
• Open the cabinet doors.
• Ensure there is no dangerous voltage present by measuring the voltage of the input
terminals and the intermediate circuit terminals.
5.2 POWER CABINET MAINTENANCE (BUSBARS+PROTECTIONS)
• 6 months after commissioning and every 2 years thereafter:
o Checking the tightness of the connections at the terminal strip.
• Every year:
o Air filter checking and replacement if needed.
• Every 6 years:
o Cooling fan (ZV003) and heating blowers change (ZV001, ZV003).
To see detailed operations on each point, see “Maintenance” paragraph of the “Hardware
manual”
5.3 CONVERTER CABINET MAINTENANCE
• Every 6 months:
o Heatsink temperature check and cleaning.
• 6 months after commissioning and every 2 years thereafter:
o Checking the tightness of the connections at the terminal strip.
• Every year:
o Air filter checking and replacement if needed.
• Every 3 years:
o Power connections check and cleaning.
• Every 6 years:
o Cooling fan change (one per module)
• Every 6 years:
o APBU branching unit -Memory backup battery renewal.
To see detailed operations on each point, see “Maintenance” paragraph of the “Supplement
to ACS800-67 Hardware Manual_Rev B” Manual
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Title: MAINTENANCE MANUAL CONVERTER CABINET G8X DTC
5.4 FG008 CIRCUIT BRAKER MAINTENANCE
• Open the circuit-breaker and check that the operating mechanism springs are discharged
• Every six months or after a trip under short-circuit:
o General inspection of circuit breaker.
• Every 6 months:
o External visual check.
o Power section inspection.
• Every 6 months or 10000 operations:
o Maintenance of the operating mechanism.
• Every 6 months:
o Check of release trip.
To see detailed operations on each point, see “Maintenance” paragraph of the “Supplement
to ACS800-67 Hardware Manual_Rev B” Manual
6 OVERVIEW OF THE CONVERTER CABINET AND COMPONENTS
6.1 FG008 Cabinet
-L1, L2, L3, connection with the secondary of the transformer 690 v, primary 20 kv.
From the switchgear (ground) the hose is rise up to the primary of the transformer.
-FS051A.A, FS051A.B, FS051A.C, fuses and overvoltage protections.
-FG008, air circuit breaker. Only opens after alarm. Set in the start-up. During
maintenance works the breaker must be locked. After handling works make sure
that the breaker is always open.
-BT003, PT100 connected to the NDCU board, to control the FG008 cabinet
temperature.
-BT001, thermostat 10º.
-BH001, hygrometer 80%.
-ZV002, ZV001, heaters. High humidity is recommended bypass N1 and N2, with that
we are increasing the power.
-ZV003, power cabinet fan.
-TI001 y TI002, current transformers to measure in phases U y W. Connected to the
NUIM board. With these measurements the converter calculates the stator power.
Beware of the polarity, red wire goes to S1 and black to S2.
- KM052E, stator contactor. Manage the grid couple and discouple. Open or close after
command is received with 200ms delay.
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6.2 FF005 Cabinet
-FF005, switch and fuses to feed the modules cabinet (690Vac). Keep open
while we are working with modules.
6.3 FG002 Cabinet
-FG002, auxiliary power protection.
-L1, L2, L3, 690 Vac three-phase power, fed from busbars in top side of FG008 Cabinet.
-TI034 y TI035, current transformers to know auxiliary power, calculated by grid
analyzer located in Top Cabinet. The Grid Analyzer communicates with PLC Phoenix.
The PLC knows the stator power and the auxiliary power therefore calculate the real
power.
-FS051B.A, FS051B.B, FS051B.C, Lightning arrester.
-FG077, auxiliary power protection. This circuit breaker is fed from the bottom side. This
is to prevent the spread of fire in case of short circuit.
-FG004, feed motors operation 690 v.
-FG010A, 690 Vac PLCs power supply.
-FG010B, 690 Vac PLCs power supply with out UPS.
-FG063, crane and high temperature kit 690 Vac power supply.
-FG0061, elevator and ground 690 Vac power supply.
-FG003, NUIM board protection, stator measurement.
-FG001, NUIM board protection, grid measurement.
-FM009A, 230 Vac PLC power supply.
-FM009B, 230 Vac PLC power supply.
-FM006, heaters protection.
-KR006, heaters contactor.
-X0, 11, 12, 13, terminal blocks.
-BT002, thermostat to control FG008 cabinet fan, 50ºC.
-KA2, time relay to open switchgear. Trips after 0,5sec if FG008 is closed after open
command.
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6.4 Control Cabinet (sliding frame)
-E1, hygrometer, 80%.
-E2, thermostat, 10ºC.
-E3, thermostat, 55ºC.
-ISU Board:
-A43, RDCU, need to upload firmware. Controls Grid Side Converter
-A433, RDCO, fiber optic communications board.
-A415, branching unit, with one NDCU exit control two INU modules through this board.
-U10, 24 Vdc 3 A power supply to feed electronic components.
-INU Board, NDCU, converter main CPU, need to upload firmware.
Two boards inside:
-A41, fiber optic communications board, communications with other
converter components.
-A42, digital input/output board, analog input/output board.
-A412, NETA board, Ethernet Communications with converter. Set with an IP address.
We can communicate with any converter in the same network, changing parameters,
seeing faultlogger and set dataloggers.
-A419, NTAC board controls generator speed, from encoder to NDCU board.
Change copper Communications to FO communications.
-F11, Electronic protection switch.
-F12, heaters protection switch.
-U11, +15/-15 v DC 1 A NUIM Power supply.
-K3….K11, relays.
-K14, K15, K16, KA1, new relays after contactor improvement.
-K22, KM052E time relay, 200ms delay.
-F15, pre-charge fuses.
-Z3, 230 Vac control voltage filter.
-K2, pre-charge contactor.
-R1, pre-charge resistor, 5 ohms.
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6.5 Power Modules Cabinet
-U6, active crowbar. Passive crowbar by setting parameters.
-R2, crowbar resistor, the power goes through this resistor to protect the converter.
-A45, NUIM board measures grid voltage, stator voltage and stator current. In
50Hz converters must cut resistors from R80 to R85, in 60 Hz converters not
necessary, as we can read in the board.
-U1, ISU module, rectifier or grid side converter, transform 690 Vac in 1070 DC with 6
IGBTs in each phase.
-U4, LCL filter, reactances and capacitors.
-U11.1, U11.2, INU modules, inverters or rotor side converter, both converters work at
the same time to feed the generator.
-K1, 690Vac main contactor.
-X01.1, 2, 3, 4, electrical connection between modules and bars.
-F1, F5.1, F5.2, DC fuses.
-U2, V2, W2, electrical connection with rotor side.
-1X, terminal blocks.
6.6 Inverter module (ISU/INU)
-C200, capacitors, 5100uF ± 10%, replace if it is out of range.
-Z1, output filter inductor. V2 modules with air core and V1 modules with iron core (20
Kg heavier).
-C211-213, C221-223, C231-233, snubbers, capacitors, improve the opening and
closing of IGBTs gates.
-A28, AFCB, protection fuse. Replaced by NRED.
-A43, APOW, new power supply.
-A42, AINT, Communications board between module and NDCU/RDCU control board.
-A435, AHCB, heating control board.
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-A433, AFPS, fan power supply.
-A432, AFIN, control the module fan speed. AINT board send the working speed.
-A21/V21, A22/V22, A23/V23, driver+igbt module, one module per phase, can not be
separated. Consists of 6 igbts. Two types:
-AGDR-61, V1 converters
-AGDR-71, V2 converters
-R21, R22, R23, discharge resistors. Between 1-3 point, resistance measurement
should be 24KΩ.
-R321,R322,R323, output filter resistor, 5Ω.
-U31,U32,U33, current transformer.
-C31,C32,C33, filter capacitor set, 2200pF.
-A311, AOFC, output filter board.
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7 ANNEXES
7.1 Pictures
CONVERTER CABINET
NOTE: Converters serial number higher than X0710XXXXX, week 10 of year 2007,
V2 converter. Converters with lower serial number are V1.
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Title: MAINTENANCE MANUAL CONVERTER CABINET G8X DTC
ISU/INU MODULE
NOTE: Converters serial number higher than X0710XXXXX, week 10 of year 2007,
V2 converter. Converters with lower serial number are V1.
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Title: MAINTENANCE MANUAL CONVERTER CABINET G8X DTC
FG008 CABINET
FS051A Lighting arrester GP012971
FF051 Protection fuses 250A GP011836
FG051 Circuit breaker 50552
BT003 PT100 GP014680
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FG008 Air circuit braker GP012968/GP036987
(1)
KM052E Stator contactor GP102875
BT001 Thermostat 10ºC GP014678
BH001 Hygrometer 80% GP014679
ZV002 Heater GP014604
TI024-TI025 Current transformers GP12969
ZV003 Fan GP014600
(1) First reference is FG008 V1, trip unit (FG008 top side) is PR-111. Second
reference is FG008 V2, trip unit PR-121.
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FF005 CABINET
FF005 Fuses 400A GP011837
SWITCH FF005 Switch GP014590
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FG002 CABINET
FS051B.A-B-C Lightning arrester GP012971
FG077 Circuit breaker 690V GP007819
FG002 Main circuit breaker 690V GP019006
FG010A Circuit breaker 690V GP021633
FG010B Circuit breaker 690V GP021635
FG004 Circuit breaker 690V GP021631
FG001 Motor circuit breaker MS325 50552
FG003 Motor circuit breaker MS325 50552
FG061 Motor circuit breaker MS325 50550
FG063 Motor circuit breaker MS325 50550
FM09A Protection switch GP014603
FM09B Protection switch GP014673
FM006 Protection switch GP014602
KA2 Time relay 0,5seg GP118114
BT002 Thermostat 50ºC GP014676
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Title: MAINTENANCE MANUAL CONVERTER CABINET G8X DTC
SLIDING FRAME
E1 Thermostat 10ºc GP011821
E2 Hygrometer 80% GP011822
E3 Thermostat 55ºc GP011821
A43 Control board RDCU GP012964
A433 DDCS Communications board GP011824
RDCO
A415 PPCS Branching unit GP011819/GP043715
(1)
U10 Power Supply 230Vac/24Vcc GP011820
A41 Control board NDCU GP012965
A42 Control board NDCU GP012965
(1) Two diferent types of branching. NPBU (V1 converter) and APBU (V2
converter).
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A419 NTAC module Pulse Encoder GP011818
Interface
A412 NETA module Ethernet Adapter GP011823
F11 Protection swicth GP012966
F12 Protection swicth GP011833
U11 220Vac/+-15Vcc Power Supply GP011830
K3-K6 K8 K9 K10 K11 Relay GP011826
K14 K15 K16 KA1 Relay GP078419
K22 Time Relay GP102892
K7 Contactor GP011834
X31 Wall Socket
K3.1 Time Relay GP057092
E11 Fan Heater GP014604
F15 Precharge Fuse GP011827
K2 Precharge Contactor GP011835
Z3 Control Voltage Filter GP012967
R1 Precharge Resistor GP011828
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POWER MODULES CABINET
U1 ISU Module GP012959/GP036984(1)
U4 LCL Module GP012960
U11.1 INU1 Module GP012959/GP036984(1)
U11.2 INU2 Module GP012959/GP036984(1)
F1 ISU Fuses 800A GP011816
F5.1 INU1 Fuses 1000A GP011817
F5.2 INU2 Fuses 1000A GP011817
(1) Converters serial number higher than X0710XXXXX, week 10 of year 2007, V2
converter. Converters with lower serial number are V1.
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R2 Crowbar Resistor GP012963
U6 Crowbar Unit GP012962
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ISU/INU MODULE
A28 AFCB Fuse board (1) GP096602
A43 APOW Power Supply (1) GP096602
A42 AINT Interface Board GP011815
A435 AHCB Heating Control Board GP021624
A433 AFPS Fan Power Supply GP011814
A432 AFIN Fan Inverter Board GP011813
(1) Provided together, AFCB + APOW.
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C231/C232/C233 Filters for the IGBTs gates GP014591
C221/C222/C223 Filters for the IGBTs gates GP014591
C211/C212/C213 Filters for the IGBTs gates GP014591
A23/V23 IGBT Module + Driver GP011810/GP036986(1)
A22/V22 IGBT Module + Driver GP011810/GP036986(1)
A21/V21 IGBT Module + Driver GP011810/GP036986(1)
R410-R413 Heating Set GP067968
(1) First reference IGBTs with driver AGDR-61C (converter V1). Second one driver AGDR-
71C (converter V2). Keep in mind that they are not compatible. Install the same driver in
both INU modules.
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R21/R22/R23 Power Resistor GP014592
R321/R322/R323 Output Filter Resistor GP014597
U31/U32/U33 Current Transducer GP011811
C31/C32/C33 Filter Capacitor Set
A311 Output Filter Board GP011831
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Z1 Output Filter Inductor GP055339
C200 Capacitor GP014601
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7.2 Drawings
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7.4 References
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1.8-3KV WIRES
WIRES QUANTITY LENGTH TERMINAL REFERENCE
L1-FF005:6 2 3 METERS 70*12MM GP086147
L2-FF005:4 2 2.90 M 70*12MM GP086148
L3-FF005:2 2 2.80 M 70*12MM GP086149
L1-FF005:5 1 1.40 M 95*12MM GP086150
L1-FF005:5 1 1.45 M 95*12MM GP086153
L2-FF005:3 1 1.30 M 95*12MM GP086151
L2-FF005:3 1 1.35 M 95*12MM GP086154
L3-FF005:1 1 1.20 M 95*12MM GP086152
L3-FF005:1 1 1.30 M 95*12MM GP086151
CROWBAR
U 1 2.08 M 16*8MM GP088599
CROWBAR
V 1 2.10 M 16*8MM GP088600
CROWBAR
W 1 2.14 M 16*8MM GP088601
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