EN / Converter Modules With Electrolytic DC Capacitors In .

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ABB low voltage AC drives, wind turbine converters and solar invertersCapacitor reforming instructionsConverter modules with electrolytic DC capacitors in the DC link

2012 ABB Oy. All Rights Reserved.3BFE64059629 Rev EENEFFECTIVE: 2012-03-21

3Table of contents1. IntroductionApplicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ABB low voltage AC drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ABB wind turbine converters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ABB solar inverters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .About capacitor reforming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .How to check the converter age . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .555666672. Reforming the capacitorsMethod 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Method 2 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Method 2 B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Reforming time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Further informationProduct and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15151515

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Introduction 51IntroductionApplicabilityThis manual applies to converter modules which have electrolytic DC capacitors in the DClink. The subsections below list the converter module types and product series in moredetail for each product area. All converter module types are referred to as converter orconverter module in this manual.Note: A drive (module) is used in all connection diagrams. The connection principle is thesame for the other converter module types as well, considering that the terminal markingsmay vary. ABB low voltage AC drivesThis manual applies to drive, inverter, IGBT supply and three-phase brake modules inproduct series ACS800, ACS850, ACQ810, ACSM1 and ACS880, ie, the following moduletypes: ACS800-01, -02, -04, -104 and -104LC ACS800-11 and ACS800-31ACS850-04ACQ810-04ACSM1-04 and ACSM1-204ACS880-01, -04 and -104. ABB wind turbine convertersThis manual applies to line-side converter modules and generator-side converter modulesin product series ACS800-67LC, ACS800-77LC, ACS800-87LC and ACS800N-87LC.Note: ACS800-67 and ACS800-77 modules include filmcapacitors in the DC link insteadof electrolytic capacitors.The film capacitors do not need to be reformed.

6 Introduction ABB solar invertersThis manual applies to solar inverter modules in product series PVS800-57.About capacitor reformingConverter DC link capacitors need to be reformed (re-aged) if the converter has been nonoperational for more than one year. Without reforming, capacitors may get damaged whenthe converter starts to operate. It is recommended to reform the capacitors once a year.Besides the reforming methods presented in this manual, ABB can supply you with readymade reforming devices, such as FINERO FST-DCP 1500-05 and FUG HCK 800-2000.For more information on purchasing these devices, contact your local ABB representative.How to check the converter ageConverter serial number defines the week when the converter was manufactured: 7 digits: For example, in 3260034, 3 denotes manufacturing year (2003), 26manufacturing week and 0034 running manufacturing number. 8 digits: For example, in 14250125, 1 denotes manufacturing country (1 Finland), 4manufacturing year (2004), 25 manufacturing week and 0125 running manufacturingnumber. 10 digits: For example, in 1063200725, 1 denotes manufacturing country, 06manufacturing year (2006), 32 manufacturing week and 00725 running manufacturingnumber.Safety instructionsWARNING! Neglecting the following instructions may cause physical injury ordeath. All electrical installation and maintenance work on the converter should be carried outby qualified electricians only. Never work on the converter, motor cable or motor when input power is applied. Afterdisconnecting the input power, always wait for 5 minutes to let the intermediate circuitcapacitors to discharge before you start working on the converter, the motor or motorcable. Always ensure by measuring with a multimeter (impedance at least 1 Mohm) that:1. voltage between converter input phases U1, V1 and W1 and the frame is close to0 V.2. voltage between terminals UDC and UDC- and the frame is close to 0 V.Never switch on the converter power supply while the reforming circuit is connected.Lock the disconnector (if any) to an open position. Ensure that the converter is clean and dry (no condensation) before starting thereforming.In addition to the safety instructions given above, follow all safety instructions deliveredwith the converter or given later in this manual. The complete safety instructions are givenat the beginning of the Hardware manual.

Introduction 7ReaderYou are expected to know the standard electrical wiring practices, electronic components,and electrical schematic symbols.

8 Introduction

Reforming the capacitors 92Reforming the capacitorsMethod 1Use method 1 for capacitor reforming if the converters have been stocked (nonoperational) for less than two years.1. Switch the power on to the converter for the time indicated in section Reforming timeon page 13.2. Do not load the converter while the reforming is ongoing.The converter “wakes up” its capacitors on its own, after which it is ready for use.Method 2 AUse method 2 A or method 2 B (page 11) for capacitor reforming if the converters havebeen stocked (non-operational) for two years or longer.WARNING! Never switch on the converter power supply while the reformingcircuit is connected. Lock the disconnector (if any) to an open position.WARNING! Only a qualified electrician is allowed to do the work. Read and followthe instructions below. Neglecting the instructions may cause physical injury ordeath.1. Ensure that the converter module is disconnected from all possible power sources (allAC and DC inputs/outputs are disconnected).2. Ensure by measuring that the converter is dead (terminals U1, V1, W1, UDC , UDC-,U2, V2 and W2).

10 Reforming the capacitors3. Compose a reforming circuit (see the diagram and data below) and connect it to theDC terminals of the converter module.4. Switch on the reforming circuit for the time defined in section Reforming time on page13.Note: Limit the reforming current to max. 500 mA. If the DC power supply does nothave an adjustable current limiter, increase the voltage gradually from 0 to a full scalevalue.5. Switch off the reforming circuit.6. Wait for 5 minutes to let the converter DC capacitors discharge.7. Ensure by measuring that the DC terminals of the converter are dead.8. Disconnect the reforming circuit from the converter.Regulated DC power with active current limiting: Output current: 0.5 1 A DC, max. 500 mA during reforming Output voltage: adjustable 0 1000 V DC. An appropriate voltage during reforming is1.35 1.45·Ux. Ux denotes the nominal AC voltage of the converter.WARNING! Capacitors may be damaged if excessive DC voltage is used duringreforming.An external resistor is not needed if the DC power supply has an adjustable current limiter.DCsupplyDC powerPower supply0.5 AA.1DC0.5. 1AA10001000VVDCR 100 Ohm / 500 WDisconnectSUPPLYSUPPLYUNITINVERTERUDC ERTERU1U2

Reforming the capacitors 11Method 2 BUse method 2 B or method 2 A (page 9) for capacitor reforming if the converters havebeen stocked (non-operational) for two years or longer.WARNING! Never switch on the converter power supply while the reformingcircuit is connected. Lock the disconnector (if any) to an open position.WARNING! Only a qualified electrician is allowed to do the work. Read and followthe instructions below. Neglecting the instructions may cause physical injury ordeath.1. Ensure that the converter module is disconnected from all possible power sources (allAC and DC inputs/outputs are disconnected).2. Ensure by measuring that the converter is dead (terminals (U1, V1, W1, UDC , UDC-,U2, V2 and W2).3. Compose a reforming circuit (see the diagram and table below) and connect it to theDC terminals of the converter module.4. Switch on the AC power supply of the reforming circuit for the time defined in sectionReforming time on page 13.5. Switch off and disconnect the AC power supply of the reforming circuit.6. Wait for 5 minutes to let the converter DC capacitors discharge.7. Ensure by measuring that the DC terminals of the converter are dead.8. Disconnect the reforming circuit from the converter.

12 Reforming the capacitorsUxxUACRDisconnectSUPPLYSUPPLYUNITUDC-UDC LECONVERTERU1U2Recommended componentsARC200 V U 240 VSKD 82/16220 Ohm / 700 W22 nF / 2000 V380 V U 415 VSKD 82/16220 Ohm / 700 W22 nF / 2000 V380 V U 500 VSKD 82/16470 Ohm / 1200 W22 nF / 2000 V525 V U 690 VSKD 82/16680 Ohm / 1700 W22 nF / 2000 V

Reforming the capacitors 13Reforming timeThe intermediate circuit (DC link) of the converter is connected to its nominal voltage forthe reforming time to “wake up” the capacitors. The reforming time required depends onhow long the converter has been stocked (non-operational), as depicted in the followingdiagram.Capacitor reforming timeReformingtimetimein hoursFormingin hours6543210021Method1 1Method34Method2 2MethodNon-operationaltimetimein yearsNon-operationalin years56

14 Reforming the capacitors

Further informationProduct and service inquiriesAddress any inquiries about the product to your local ABB representative, quoting the typedesignation and serial number of the unit in question. A listing of ABB sales, support andservice contacts can be found by navigating to www.abb.com/drives and selecting Sales,Support and Service network.Product trainingFor information on ABB product training, navigate to www.abb.com/drives and selectTraining courses.Providing feedback on ABB Drives manualsYour comments on our manuals are welcome. Go to www.abb.com/drives and selectDocument Library – Manuals feedback form (LV AC drives).Document library on the InternetYou can find manuals and other product documents in PDF format on the Internet. Go towww.abb.com/drives and select Document Library. You can browse the library or enterselection criteria, for example a document code, in the search field.

ABB OyDrivesP.O. Box 184FI-00381 HELSINKIFINLANDTelephone 358 10 22 11Fax 358 10 22 22681www.abb.com/drivesABB Inc.Automation TechnologiesDrives & Motors16250 West Glendale DriveNew Berlin, WI 53151USATelephone262 785-32001-800-HELP-365Fax262 780-5135www.abb.com/drivesABB Beijing Drive Systems Co. Ltd.No. 1, Block D, A-10 Jiuxianqiao BeiluChaoyang DistrictBeijing, P.R. China, 100015Telephone 86 10 5821 7788Fax 86 10 5821 7618www.abb.com/drives3BFE64059629 Rev E (EN) 2012-03-21Contact us

ABB wind turbine converters This manual applies to line-side converter mo dules and generator-side converter modules in product series ACS800-67LC, ACS800-77LC, ACS800-87LC and ACS800N-87LC. Note: ACS800-67 and ACS800-77 modules include filmcapacitors in the DC link instead of electrolytic capacitors.The film capacitors do not need to be reformed.

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