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M E D I U M VO LTAG E W I N D CO N V E R T E R S

ABB wind turbine converters

PCS6000, full power converter,
up to 12 MW
2 ABB WIND POWER SOLUTIONS, PC S60 0 0 WIND TURBINE CONVERTERS
 ABB WIND POWER SOLUTIONS, PC S60 0 0 WIND TURBINE CONVERTERS 3

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PCS6000 medium voltage
wind turbine converter
Proven technology for efficient operation of large wind turbines
and lowest levelized cost of energy.

Medium voltage converters for power plants and many other demanding
large wind turbines applications. The first PCS6000 Wind was
The growing importance of regenerative energy delivered in 2006.
is accompanied by a rise in the demand for wind
power. Wind turbines are today attaining such The ABB approach – more than delivering
high power ratings that a medium voltage system a product
is the optimum choice. It allows a higher energy From the early evaluation phase of a new wind
production through reduced losses in the turbine to final operation in the wind farm, ABB
electrical drivetrain and lower installation costs provides first-class customer consulting,
by eliminating expensive cable runs. support, training and services.

Perfect match for large-scale wind turbines ABB’s converter specialists are experts in all
ABB’s medium voltage wind turbine converter aspects of the electrical system and will build
is the perfect match for large-scale offshore a drivetrain that functions perfectly – from the
wind turbines. Available up to 12 MW, it can be generator through to grid integration.
operated with permanent magnet and
induction generators. Its compact footprint ABB’s life cycle management involves a highly
allows nacelle or tower installations. qualified service team and supporting software
tools for remote monitoring. They will maximize
Lowest cost of energy the value of the equipment by maintaining
The PCS6000 helps to utilize the full potential of trouble-free operation and ensuring maximum
wind energy, reliably and economically. It lowers availability.
the levelized cost of energy (LCoE) through
maximum availability, high efficiency, advanced PCS6000 features
grid code compliance and easy maintenance. • Full power converter for wind turbines
up to 12 MW
Technology proven worldwide • High efficiency due to medium voltage
The PCS6000 wind turbine converter is based on technology
ABB’s medium voltage frequency converters • High availability due to low parts count and
which are installed in thousands of applications long-life components
worldwide. With their excellent reputation for • Low life-cycle costs
reliable operation in the harshest environments, • Modular design for easy customization
the converters are used in industrial and • Advanced support and remote service tools
propulsion drive systems, railway grid entities, for enhanced reliability, availability and
static VAr compensators, battery storage, tidal performance

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The PCS6000 platform
is used in a wide
range of applications,
such as railway grid
entities and tidal power
generation (photo ©
Atlantis Resources)
4 ABB WIND POWER SOLUTIONS, PC S60 0 0 WIND TURBINE CONVERTERS

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Superior system performance
The PCS6000 offers several features that ensure efficient and
reliable turbine operation and grid code compliance.

Full generator control Gentle generator handling Full grid control

Optimal generator power control Reduced mechanical stress due to Advanced active and reactive grid
for maximum energy production drivetrain damping, resulting in a power control ensures grid code
at any turbine speed. longer lifetime of the equipment. compliance at any time.

Dynamic braking chopper High and low voltage ride-through Motor operation
Low voltage ride-through and safe Keeps the turbine on-line even Enables hall test, back-to-back
and smooth turbine shutdown, during a major grid disturbance. testing and precise rotor
even with a lost grid. positioning, simplifying
testing and service tasks.

Precharging soft start Flexible harmonic spectrum Island mode operation

Enables zero-current, flicker- and Easy adaptation to different grid Ensures electricity supply to the
inrush-free grid synchronization. systems to avoid harmonic wind turbine’s auxiliary systems
resonance problems. when the turbine is not connected
to the grid.

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01 a Generator

b Generator disconnector

c du/dt filter

G d Generator converter

a b h e DC link / braking chopper

Filter Filter f Grid converter

g Line filter
c g
h Transformer / circuit breaker
d e f

— The PCS6000 has a number of features that at the same time, reducing the mechanical stress
01 PCS6000 converter
topology maximize energy production, increase the on the drivetrain. It also lays the foundation for
lifetime of the equipment and ensure grid code grid code and fault ride-through compliance.
compliance.
Motor operation for full-speed generator testing
ABB’s high-performance AC 800PEC controller allows efficient testing of turbine components.
ensures fast and precise control of the PCS6000’s It also enables precise rotor positioning which
generator-side and grid-side converters. This facilitates installation and allows easy and safe
enables maximum energy production, while, access to the turbine for maintenance.
 ABB WIND POWER SOLUTIONS, PC S60 0 0 WIND TURBINE CONVERTERS 5

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High reliability and availability
The PCS6000 provides reliable operation in the harshest
environments thereby minimizing maintenance.

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Low parts count 02 Line filter resistor Grid Generator Generator du/dt
No paralleling of components for and capacitor converter converter disconnector filter

a higher reliability and a smaller

footprint.

Note:
Cooling
unit
in back
Long-life components
Extend component replacement
intervals considerably, lowering
the converter’s life cycle costs.

Line filter DC link Braking

reactor capacitors chopper

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03 Easy maintenance
Easy access to all converter
components reduces the cost and
time required for maintenance.

Fuseless design Filterless design Support and remote service tools

Avoids site visits for fuse Increases reliability and efficiency Enhance the converter’s reliability,
replacement after disturbances when it comes to higher power availability and performance,
and ensures a remote restart ratings. reducing downtime and lowering
after a cleared failure. LCoE.

— For large turbines, ABB’s PCS6000 medium the PCS6000 is a market reference for long life
02 Clear design with
low parts count voltage technology is the right platform. and operational reliability.
— Significantly lower currents result in a boost in
03 Small cross-section
of tower cabling efficiency, a lower parts count increases reliability, It is the most sustainable, efficient and economic
and a smaller footprint along with easy cabling choice for top performance, grid stability and
and fast installation reduces CAPEX. trouble-free operation.

With the emphasis on a well-balanced converter

design and the use of high-quality components,
6 ABB WIND POWER SOLUTIONS, PC S60 0 0 WIND TURBINE CONVERTERS

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Modular design for high flexibility
The PCS6000’s modular design enables tower and nacelle
installations and easy customization.

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01

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02

In-line Face-to-face T-shape

— Modular design for easy customization Fits confined spaces

01 Standardized modules
are easily combined for The PCS6000 is a modular frequency converter The converter’s modularity allows a tailored
customized solutions that is ideal for demanding single- or multi- mechanical arrangement of the components,
up to 12 MW
— generator applications. The design concept depending whether it is placed in the tower,
02 The modularity allows maximum flexibility at different power the nacelle or a separate container outside
permits a flexible
arrangement of the ratings. Standardized modules can be combined the turbine. Placing it in the tower results in
converter modules for customized solutions with minimum a reduction in nacelle weight and easier
even on a single deck
– either in-line, face- prototyping and engineering effort. service access.
to-face or T-shape
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ABB wind turbine drivetrain packages
ABB provides optimized electrical drivetrain packages, including
generator and converter, that work in perfect synchronization.

ABB’s drivetrain experts support turbine Comprehensive testing

manufacturers in designing and dimensioning ABB is committed to ensuring the reliability of
the drivetrain components and provide support every wind turbine drivetrain package it delivers.
in the grid code certification process. To ensure that quality standards and customer
requirements are fully met, the equipment is
ABB generators subjected to thorough testing and simulations
ABB has supplied more than 35,000 generators in ABB’s test facilities.
over the last 30 years to leading wind turbine
customers worldwide. It offers a complete range In addition, ABB is able to perform tests of
of wind turbine generators, supporting all the complete drivetrain to verify its performance
drivetrain concepts. ABB has been the leader and grid code compliance. This simplifies turbine
in permanent magnet generator (PMG) certification and reduces on-site testing costs.
technology since the 1990s.
Grid code compliance
The standard power range is from 1 to 12 MW, The wind turbine converter plays a central
with generators available up to 20 MW and 15 kV. role in the turbine’s grid code compliance.
The PCS6000 is subjected to fault ride-through
ABB generators are designed for harsh operating and power quality tests to ensure grid code
conditions. The high performance insulation compliance. Comprehensive real-time simulations
system and the rigid form-wound windings of typical grid disturbances are performed to
guarantee a long lifetime with high overload ensure the PCS6000 can withstand grid
capability, even with the continuously changing disturbances and complies with all standards.
loads common to wind turbines. The bearing This simplifies turbine certification and cuts
construction is designed for reliable operation on-site testing costs.
with long service intervals.
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Service and support
The PCS6000 is backed by comprehensive life-cycle services
that ensure trouble-free operation and maximum availability.

ABB engineers not only work with turbine Preventive maintenance

manufacturers during the design and converter Implementing ABB’s converter-specific preventive
specification phase, but provide their services maintenance schedules reduces the risk of failure
throughout the entire life cycle of the converters. and increases the lifetime of the converter,
lowering overall operational costs. ABB’s
Installation and commissioning preventive maintenance kits contain all the
ABB provides dedicated converter training for genuine ABB spare parts needed for a specific
installation and commissioning for wind turbine maintenance task, simplifying preventive
manufactures. ABB can support turbine maintenance.
manufacturers during installation and
commissioning. Its certified commissioning Dedicated support and remote service tools
engineers have extensive knowhow and ABB’s PCS Service Suite is an intelligent
experience. monitoring and service tool that allows trained
and authorized customers to monitor wind
Technical support turbine converters remotely, identify possible
ABB provides remote services for fast failure performance issues at an early stage and initiate
analysis as part of its maintenance program. service tasks.
On customer request, a 24/7 support line and
on-site field support can be provided. The tool significantly enhances the converter’s
reliability, availability and performance, reducing
Training unplanned downtime and lowering the levelized
ABB provides a wide selection of wind turbine cost of energy (LCoE).
converter training to turbine manufacturers and
wind farm operators.
SERVICE AND SUPPORT 9

Spares and consumables Services for ABB wind turbine converters

Having the right spare parts available at • Installation and commissioning
the correct locations needs to be well planned • Grid integration support
to ensure the highest wind turbine energy • On-site support
production. ABB can help plan spare part • Training
stocking throughout the life cycle of the • Remote diagnostics
wind turbine. • 24/7 support line
• Maintenance
Service agreements • Customized maintenance contracts
Depending on the needs of the turbine • Spare parts and logistics network
manufacturer or wind farm operator, ABB •
can bundle individual services in one contract. Benefits
A contract can be made at any stage of the • Reduced down- and recovery time
wind turbine converter’s service life. • Lifetime extension of converter
• Enhanced operational efficiency
Global network, local presence • Lowered capital expenditure
ABB’s global presence and worldwide • Improved cost control
organization, with its network of selected
partners, provide local support, training
and services as and when required.
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Data sheet PCS6000

Converter model PCS6000 Wind Electrical interface

Converter type 3-level, 4Q, VSI-NPC, fuseless design Generator-side From top (Pfisterer P3)
connections
Power range up to 12 MW
Grid-side connections From top (Pfisterer P3)
Nominal voltage 3.3 kV
Braking resistor From back (Pfisterer P3)
Semiconductor type IGCT connections
Capacitors Self-healing and self-protected film Control connections From bottom (terminals inside
capacitors control cabinet)
Supported generators High-, medium- and low-speed
Enclosure
permanent magnet generators,
asynchronous induction generators, Constructional design 1.5 mm carbon steel,
static-excited synchronous generators edge bended sheets
on solid base-frame MNS system,
Cooling riveted and bolted
Converter cooling Closed-loop cooling unit with
Degree of protection IP54
deionized water / glycol mix coolant
Enclosure color RAL 7035
Coolant inlet temperature Up to 45 °C 1)
Pumps 1 pump or 2 pumps with Corrosion protection Powder and / or zinc coating
automatic changeover Door locking Mechanical security interlocking door
Heat exchanger Water-air (external) / release when grounded
water-water (internal) Anticondensation Humidity-, temperature sensor, control
Instrumentation / Temperature, pressure, logic and space-heater protection
transmitters conductivity Lifting Bottom lifting with removable eyebolts
Deionization Automatic by deionizer resign Environmental limits
Deaeration Automatic by deaeration valve Ambient temperature Transport -25 to +70 °C
Storage -25 to +55 °C
Temperature control Control logic / motor-driven valve
Operation -10 to +45 °C 3)
Braking chopper / resistor
Altitude 0 to 1000 m
Chopper semiconductor IGCT
Product compliance
Braking resistor capacity 15 MJ / 30 MJ 2) Product markings CE (acc. 2014/35/EU, 2014/30/EU)
Braking resistor size 1160 x 670 x 660 / 1160 x 670 x 1030 DNV-GL (acc. GL-IV-2:2012)
(LxWxH mm) CGC (acc. CGC-R46022:2011)
Braking resistor weight ~ 200 kg / ~ 400 kg Quality management system ISO 9001:2008
Braking resistor cooling Ambient air Environmental
ISO 14001:2004
management system
Control
Occupational health and OHSAS 18001:2007
Controller ABB
safety management system
Generator-side control Pulse width modulation
Grid-side control Optimized pulse pattern
Fieldbus interface Profibus DP, Profinet IO, Modbus TCP,
EtherCAT, CANopen
Ethernet Service and maintenance access with
software tool for Windows via installed
IPC; VPN remote access ready
Transient recorder Ring buffer, high resolution
Service IPC Trending, data logger, remote access
Operation modes Off / standby / production
Generator-side setpoints Power factor / reactive power
Special operation modes Positioning / test / static VAr
compensation / island mode
Local control Emergency off
Local indication Production, grid disconnector closed,
DC link switch closed / released,
rotor locked
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Example configurations
Power rating 4)  7 MW / 8.5 MVA  10 MW / 12 MVA  12 MW / 14.5 MVA 5)
Generator winding system Single Single Double
Nominal generator voltage 3.3 kV 3.3 kV 3.3 kV
Generator-side voltage range 0 to 3.4 kV 0 to 3.4 kV 0 to 3.4 kV
Grid-side voltage range 0 to 3.4 kV 0 to 3.4 kV 0 to 3.4 kV
Number of IGCTs 12 + 12 12 + 24 24 + 24
Nominal generator-side frequency range 0 to 120 Hz 6) 0 to 120 Hz 6) 0 to 120 Hz 6)
Grid-side frequency 50 or 60 Hz 50 or 60 Hz 50 or 60 Hz
Efficiency at converter’s rated point ~ 0.98 % ~ 0.98 % ~ 0.98 %
Generator-side du/dt < 1.5 kV/µs < 1.5 kV/µs < 1.5 kV/µs
Grid-side filter Sine filter du/dt filter du/dt filter
Dimensions
In-line arrangement (LxWxH mm) 4960 x 1280 x 2460 5160 x 1280 x 2460 5960 x 1280 x 2460
T-shape arrangement (LxWxH mm) On request 4360 x 2100 x 2460 5160 x 2100 x 2460
Face-to-face (two cabinets) arrangement 3550 x 1280 x 2450
(LxWxH mm) 1450 x 1080 x 2450 on request on request
Back-to-back arrangement (LxWxH mm) 3550 x 2280 x 2450 on request on request
Weight ~ 5300 kg ~ 6200 kg ~ 7300 kg
Coolant connections DN80 from top DN80 from top DN80 from top
Auxiliary supply
Auxiliary supply voltage 3-phase, 400 V, 3-phase, 400 V, 3-phase, 400 V,
50 or 60 Hz 50 or 60 Hz 50 or 60 Hz
Auxiliary supply power ~ 8 kW ~ 8 kW ~12 kW

Notes:
1)
Higher temperatures possible on request
2)
Other braking resistor capacities possible on request
3)
Other ambient temperatures possible on request
4)
Power rating indicative (depends on generator frequency, cooling and grid code requirements)
5)
Redundant version possible on request
6)
Other generator-side frequencies possible on request
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For more information, please contact
your local ABB representative or visit

abb.com/power-converters-inverters/wind-turbines
abb.com/windpower

PCS6000 webpage

Additional information
We reserve the right to make technical changes or
modify the contents of this document without prior
notice. With regard to purchase orders, the agreed
particulars shall prevail. ABB does not accept any
3BHS351272 E01 REV C 24.1.2019

responsibility whatsoever for potential errors or

possible lack of information in this document.

We reserve all rights in this document and in the

subject matter and illustrations contained therein.
Any reproduction, disclosure to third parties or
utilization of its contents – in whole or in parts – is
forbidden without prior written consent of ABB.

© Copyright 2019 ABB. All rights reserved.

Specifications subject to change without notice.