PCS 6000 for large wind turbines

Medium voltage, full power converters

up to 9 MVA
ABB medium voltage converters – operating successfully
in thousands of installations

The growing importance of regenerative energy has been For any large-scale wind turbine, the PCS 6000 medium
accompanied by a continuous rise in the demand for voltage converter is the perfect match when operating
wind power. However, state-of-the-art turbines are now with synchronous and asynchronous generators – whether
attaining such high power ratings that low voltage high- medium- or low-speed designs.
systems are struggling to cope with the currents and
losses occurring in generators, converters and cables. The PCS 6000 approach – more than delivering a product
From the early evaluation phase of a new wind turbine to final
The logical solution is to use medium voltage converters in operation in the wind park, ABB provides first-class customer
large wind turbines – with real benefits when it comes to consulting, support, training and service.
hardware and system performance.
ABB converter specialists are experts in all aspects of the
Over the years, medium voltage technology has become well system and will therefore build an electrical drive train that
established. Worldwide, ABB has been a leader in the functions perfectly – from the generator through to grid
installation of medium voltage frequency converters. ABB integration.
medium voltage converters, with their excellent reputation
for high-endurance, reliable operation in the harshest ABB’s life-cycle management involves a highly qualified
environments, are used in industrial and propulsion drive service team who can rely on supporting software tools for
systems, railway grid entities, static VAr compensators, remote monitoring. They will maximize the value of the
battery storage and many other demanding applications. equipment by maintaining trouble-free operation and ensur-
ing maximum availability.

2 PCS 6000 for large wind turbines

PCS 6000 medium voltage converters – for top system
performance and gentle turbine operation

Full generator control DC link decoupling Full grid control

For optimal active and reactive For independent grid- and generator- For optimal active and reactive
generator power control, plus max- side control without impact from one grid power control, plus guaranteed
imum wind utilization at any turbine side to the other. grid-code compliance.
speed.

Gentle generator handling Dynamic braking chopper High and low voltage ride-through
For reduced mechanical stress thanks For low voltage ride-through and safe For keeping the turbine on-line even
to optimum drive train damping, plus turbine shutdown, even with a lost during a major grid disturbance.
overspeed and overvoltage protection. grid.

Motor operation Precharging soft start Harmonic elimination

For back-to-back testing and precise For zero-current, flicker- and For reduced harmonics into the
rotor positioning. inrush-free grid synchronization. transformer and the grid.

a Generator
b Generator breaker
c du / dt filter
d Generator converter
e DC link / braking chopper
f Grid converter
a b h
g Line filter
h Transformer / circuit breaker

c g
d e f

When it comes to large turbines, ABB’s PCS 6000 medium The bottom line? With large wind turbines, the PCS 6000
voltage technology is the right choice. With significantly medium voltage, full power converter is the most sustainable,
lower currents, the result is a boost in efficiency, a lower part efficient and economic choice for top performance, grid
count, a smaller footprint along with easy cabling and fast stability and trouble-free operation.
installation.

The full power topology of the PCS 6000 gently decouples

the turbine’s mechanical drive train from the electrical grid,
and vice versa, while minimizing turbine stress and allowing
compliance with even the strictest grid codes.

PCS 6000 for large wind turbines 3

PCS 6000 medium voltage converters – fewer parts for
maximum reliability

1
Only 26 semiconductors
12 ICGTs 12 ICGTs
No paralleling of components and grid generator Grounding
Line fi lter R & C converter converter switch du/dt fi lter
therefore a lower part count, higher
reliability, less complexity and a
smaller footprint.

Condensation protection
To ensure a safe start-up even in
humid environments.

Line fi lter DC link 2 ICGTs Generator Cooling unit with

reactor capacitors braking chopper breaker 2 pumps &
3-way valve

2
Effective converter cooling
Trouble-free operation thanks to the
integrated closed-loop cooling circuit
with redundant pumps and three-way
valve.

3
Fuseless design DC link
To avoid site visits for fuse replace- Made up of high-quality, mainten-
ment after disturbances and allow ance-free industrial film capacitors
a remote restart after a cleared with a self-healing and internally
failure. fused design.

Using ABB’s medium voltage technology, the paralleling of Advanced protection and high-speed converter control
devices is not required. This keeps the part count low, are handled by ABB’s AC 800PEC controller. All system
resulting in a much lower failure rate compared to other communication is solely via fiber optical links and is
solutions operating at such a power level. therefore immune to electromagnetic interference.

With the emphasis on a well-balanced converter design and

the use of high-quality components, the PCS 6000 is a
market reference for long life and operational reliability.

4 PCS 6000 for large wind turbines

PCS 6000 medium voltage converters – for high flexibility and
modular design

4 5

Pitch
Generator Brake drive

Nacelle

Tower base

Generator
breaker
Wind turbine
controller

Frequency
converter

Converter controller

Generator Grid
converter converter

1 Clear design with low parts count Transformer

2 Much smaller cross-section of tower cabling
3 Integrated Gate Commutated Thyristor (IGCT)
4 Modular design for customized applications
5 Physical separation of generator and
Circuit breaker
converter
6 Flexible and space-saving layout

Grid

Back-to-back Face-to-face In-line

PCS 6000 modular design covers any configuration The PCS 6000 fits confined spaces
The PCS 6000 is a modular type of frequency converter Medium voltage allows easy location of the converter at the
that is ideal for the majority of demanding single- or multi- base of the tower. The resultant reduction in nacelle weight
generator applications. The design concept allows maximum and easier service access bring major wind turbine design
flexibility at different power ratings and also customized benefits.
solutions involving a minimum prototyping and engineering
effort. The modularity of the PCS 6000 permits the arrangement of
the converter modules very flexibly even on a single deck –
either back-to-back, face-to-face or in-line.

PCS 6000 for large wind turbines 5

PCS 6000 medium voltage converters – facts and figures

Converter model PCS 6000 Wind Auxiliary supply

Converter type 3-level, 4Q, VSI-NPC, fuseless design Auxiliary supply voltage 3-phase, 400 V, 50/60 Hz
Semiconductor IGCT Auxiliary supply power ~ 8 kW ~ 12 kW
Capacitors Self-healing and self-protected film capacitors
Supported generators High-, mid- and low-speed permanent magnet Cooling
asynchronous induction generator Converter cooling Closed-loop cooling unit
static-excited synchronous generator deionized water / glycol mix coolant
4)
Coolant inlet temperature Up to 45°C
Converter data Pumps 2 pumps with automatic changeover,
Converter voltage nom. 3.3 kV 4.16 kV 3.3 kV 100 % redundancy with check valves
Generator-side voltage 0 to 3.4 kV 0 to 4.3 kV 0 to 3.4 kV Heat exchanger Water-air (external) / water-water (internal)
Grid-side voltage 0 to 3.4 kV 0 to 4.3 kV 0 to 3.4 kV Coolant connections DN 50 DN65
Semiconductor type RC–IGCT RC–IGCT Sym.–IGCT Instrumentation / Temperature, pressure, conductivity
Number of IGCTs 12 + 12 transmitters
1)
Generator-side 8 – 100 Deionization Automatic by deionizer resign
frequency nom. Deaeration Automatic by deaeration valve
Grid-side frequency 50/60 Hz Temperature control Control logic / motor-driven three-way valve
Power rating 4 MVA 4.5 MVA 9 MVA
1)
other generator-side frequencies possible on request
Efficiency at converters ~0.980 2)
including cooling and generator breaker / without braking resistor
3)
rated point other arrangements possible on request
4)
higher temperatures possible on request
Generator side du/dt < 1.5 kV / μs

2) 3)
Dimensions
In-line arrangement size 5100 x 1200 x 2450 5700 x 1200 x 2450
(LxWxH mm)
Face-to-face 3300 x 1200 x 2450 3500 x 1200 x 2450
arrangement size 1800 x 1000 x 2450 2200 x 1000 x 2450
(LxWxH mm)
Back-to-back 2700 x 1200 x 2450 2700 x 1200 x 2450
arrangement size 2400 x 1000 x 2450 3000 x 1000 x 2450
(LxWxH mm)
Weight ~ 5250 kg ~ 6200 kg

Converter design cases

5)
Turbine power ratings 3 MW 4 MW 5 MW 6 MW 7 MW
Converter rating on generator side ~ 3.3 MVA ~ 4.4 MVA ~ 5.5 MVA ~ 6.6 MVA ~ 7.7 MVA
Converter rating on grid side
@ TenneT grid code ~ 3.7 MVA ~ 5.0 MVA ~ 6.2 MVA ~ 7.5 MVA ~ 8.7 MVA
@ UK grid code ~ 3.6 MVA ~ 4.8 MVA ~ 6.0 MVA ~ 7.2 MVA ~ 8.4 MVA

5)
to be clarified with coolant temperatures / generator frequency

6 PCS 6000 for large wind turbines

Generator breaker Enclosure
Type ABB VD4 X0 Constructional design 1.5 mm carbon steel, edge bended
Insulation / safety Vacuum breaker / ground switch included sheets on solid base-frame MNS system,
Rated voltage 6.6 kV riveted and bolted
Rated current 800 A 1250 A / 1700 A Degree of protection IP 54
Mechanical cycles 30000 Enclosure color RAL 7035
Corrosion protection Powder and / or zinc coating
Braking chopper / resistor Door locking Mechanical security interlocking door
Chopper semiconductor IGCT release when grounded
Braking resistor type Cast iron Anticondensation Humidity-, temperature-sensor, control logic
Braking resistor capacity 15 MJ / 30 MJ and space-heater protection
Braking resistor size 1200 x 400 x 1030 / 1200 x 650 x 1030 Lifting Bottom lifting with removable eyebolts
(LxWxH mm)
Braking resistor weight ~ 200 kg / ~ 400 kg Environmental limits
Braking resistor cooling Ambient air Ambient temperature Transport -40 to +70 °C
Storage -40 to +70 °C
7)
Control Operation -15 to +50 °C
Controller ABB AC 800PEC Altitude 0 – 1000 m
Generator-side control Pulse width modulation
Grid-side control Optimized pulse pattern Service
Field bus interface Profibus DP / DPV1, Profinet IO, Modbus TCP, 24/365 support line, product expert remote diagnostic
EtherCat, CANopen, InterBus Worldwide service and spare part network
Ethernet Service and maintenance access with software
6)
CT/VT included in HV switchgear, not in PCS 6000 scope
tool for Windows via installed IPC; VPN remote 7)
other ambient temperatures on request
access ready
Transient recorder Ring buffer, high resolution
Service IPC Trending, data logger, remote access
Operation modes Off / standby / production
Generator-side setpoints Torque / power
Grid-side setpoints Power factor / reactive power
Special operation modes Positioning / test / static VAr compensation
Local control Emergency off, local / remote control key switch
Local indication Production, grid-breaker closed,
DC link switch closed / released, rotor locked

Electrical interface
Generator-side From top (Pfisterer P3-AF01)
connections
Gide-side connections From top (Pfisterer P3-AF01)
Braking resistor From back (Pfisterer P3-AF01)
connections
Control connections From bottom (wire terminals inside
control cabinet)
6)
Grid-side transducers From high voltage side CT, VT

PCS 6000 for large wind turbines 7

Contact us

3BHS351272 E01 Rev. A

ABB Automation Products GmbH Copyright 2012 ABB. All rights reserved.
Motors and Drives Specifications subject to change
Wallstadter Strasse 59 without notice.
68526 Ladenburg / Germany
Phone: +49 6203 71 77 17
Fax: +49 6203 71 76 00

ABB Ltd. (South Korea)

Wind Renewable Team / DM
157-33 Samsung-dong, Kangnku
Seoul, Korea 135-090
Phone: +82 2528 27 89
Fax: +82 2528 23 38

ABB Beijing Drive Systems Co., Ltd.

No.1, Block D, A-10 Jiuxianqiao Beilu
Chaoyang District, Beijing, 100015
Phone: +86 10 5821 77 88
Fax: +86 10 5821 76 18

ABB Switzerland Ltd

Power Electronics
Power Converter Products
Austrasse
5300 Turgi / Switzerland
Phone: +41 58 589 32 35
Fax: +41 58 589 20 90

E-Mail: [email protected]
www.abb.com/powerelectronics