ACS 5000 Training

ACS 5000 Air Cooled

Service & Commissioning

Power Part

ACS 5000 Training -RevC2

ABB Ltd - 1 -

Course G740

ABB Ltd

Page 1

ACS 5000 Training

Power part

Objectives

Upon completion of this part the student will be familiar with:

Main circuit diagram
Location and function of components
Operation principle of 5-level topology
Communication between INU and COU

ACS 5000 Training -RevC2

ABB Ltd - 2 -

Protection functions

ABB Ltd

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ACS 5000 Training

Power part

Drive topology
Input transformer(s)

3-ph.
MV

MCB

supply

6 secondaries
10phase shift

6,10

5dv/dt

Phase 3
Phase 2

Phase 1

12 pulses diode rectifier

on each phase

H-bridge inverter
on each phase,
with a common
star point

23

ACS 5000 Training -RevC2

ABB Ltd - 3 -

2 x 3-level inverter cells

per H-bridge

INU1,INU2,INU3

ACS 5000 consists of three phase modules (INU1, INU2, INU3).

Each phase module supplies one of the motor phases, and represents the
equivalent of a single phase inverter (H-bridge), with a 12 pulses diode
rectifier as a front end.

ABB Ltd

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ACS 5000 Training

Power part

Drive topology
L_P

ACS 5000 MV Variable Frequency Drive

x1L1
x1L2
x1L3

36-pulse
Rectifier

DC-Link

x=3

MR
x2L1
x2L2
x2L3

L3

x=1

L_N1

L1

INU3

H-bridge inverter
on each phase,
with a common
star point

NP

- DC

ACS 5000 Training -RevC2

ABB Ltd - 4 -

Star
Point

+DC

IGCT with
RC diode

Motor

L2

12 pulses diode rectifier

on each phase 12

Phase

x=2

Rectifier L_N

L_P1

5-level
Inverter
and dv/dt Filter

L3

+DC

INU2

NP

- DC

L2
L1

+DC

INU1

NP

- DC

3-level inverter cell

Inverter
Star Point

126

The rectifier: 12-pulse diode bridge, consisting of two 6-pulse rectifiers in

series.
DC+,DC-NP

The rectifier provides the DC voltage: DC+, DC- and the Neutral Point NP.
The rectifier of each phase module (INU1, INU2, INU3) is supplied by two
secondaries, 30phase shift, but the overall phase shift between the six
secondaries is 10. 3010

The DC link, equipped with DC link capacitors and Grounding Switch (not
figured out here).
3

The inverter: H-bridge inverter (consisting of two 3-level inverter cells),

equipped with four IGCTs (Integrated Gate Commutated Thyristor) with
reverse conducting diodes integrated, and two Neutral Point diodes.
4IGCT2NP

ABB Ltd

Page 4

ACS 5000 Training

Power part

ACS 5000 main circuit diagram

L_P

L_P1

L_N1

L_N
L_P

L_P1

Phase module V
(=INU 2)

MR

L_N1

L_N
L_P
ACS 5000 Training -RevC2
ABB Ltd - 5 -

Phase module W
(=INU 3)

MR

L_P1

Phase module U
(=INU 1)

MR

L_N

L_N1

Three separated DC links

DC

12-pulse diode bridge per DC link

DC12

Quasi 36-pulse (here: 2x18-pulse transformer topology)

36

-20
+25

diode bridge
phase 3

0
+15

+20
+5
diode bridge
phase 2
-20
-5

0
-15

+20
-25

ABB Ltd

diode bridge
phase 1

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ACS 5000 Training

Power part

ACS 5000 Air Cooled

(=CBU)

(=COU/TEU)

(=INU3)

(=INU2)

ACS 5000 Training -RevC2

ABB Ltd - 6 -

(=INU1)

ABB Ltd

Modularity:

3.5 MVA single drive

7 MVA single drive (double size CBU)

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ACS 5000 Training

Power part

Phase module

ACS 5000 Training -RevC2

ABB Ltd - 8 -

Rectifier stack

ABB Ltd

Grounding
switch

Inverter stack

IGCT Power
Supply (IPS)

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ACS 5000 Training

Power part

Phase module (rear side)

Rectifier

Inverter

di/dt+

ACS 5000 Training -RevC2

ABB Ltd - 9 -

Clamping
resistors

ABB Ltd

du/dt Filter
Resistor

du/dt Filter
Coil

Clamping
resistors

Output CT

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ACS 5000 Training

Power part

Diode rectifier
DC+

31236

Rectifier consists of three 12pulse diode bridges forming a

36-pulse system.
The rectifier rectifies the AC
line voltage and supplies
electrical energy to the DC link
capacitors.

1L1
1L2
1L3

NP

ACS 5000 Training -RevC2

ABB Ltd - 11 -

2L1
2L2
2L3

DCRectifier

The input rectifier bridges provide DC voltage and current to the DC

link. DC LINK
They are wired in series such that their voltages are additive.

All DC bus current flows through both bridges due to the series
connection.

ABB Ltd

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ACS 5000 Training

Power part

Charging

The three DC links are charged via one common LV charging

relay and one common charging transformer.

Each DC link has got own HV charging relay.

Charging of the DC links is done in parallel at the same time.
DC LINK
+A15 -T1091

ACS 5000 Training -RevC2

ABB Ltd - 15 -

+A13 -Q1002

charging
transformer
3ph Charging
Transformer

+A15

u1

u2

-K1091
HV Relay

v1

v2

HV Relay
-K1092

w1

w2

-K1093
HV Relay

DC
(NP1)
DC(NP1)
DC
(NP2)
DC(NP2)
DC
(NP3)
DC(NP3)

LV
LVRelay
Relay

n2

Common
rail (INU)
Common
Rail

-T1091

ABB Ltd

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ACS 5000 Training

Power part

Charging sequence

MAX

DC bus charging sequence

20 s

ACS 5000 Training -RevC2

ABB Ltd - 16 -

Values

5400 VDC
5000 VDC
DC VOLTAGE

MCB order close

MIN
Time (s)

Charging sequence:
RDY ON

At the beginning Main Circuit Breaker (MCB) is off (drive status: RDY ON).
Pre-charging the DC link (capacitors) is done by using charging circuit
(charging transformer). The capacitors are charged before the converter is
connected to the main power source to avoid excessive inrush currents
(drive status: Charging).
The voltage of the DC link will rise to a defined limit (DC charging level:
5000 V). At this limit the HV relay will be opened.

MCB closing level (should be at least 100 V less than value DC charging
level) => MCB closing is enabled.
MCB100V

MCB is on and DC voltage reaches its nominal level.

MCB

ABB Ltd

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ACS 5000 Training

Power part

Discharging

In ACS 5000 Air Cooled the discharging can be done either with
balancing resistors or with optional BCU (Braking Chopper Unit).

ACS 5000 Training -RevC2

ABB Ltd - 17 -

When the DC link voltage reaches 1000 V, the drive performs a firing
through to discharge the DC link quicker. 1000V

ABB Ltd

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ACS 5000 Training

Power part

Grounding switch

In ACS 5000 there are three separate DC

links. Each DC link has its own grounding
switch. Each grounding switch has three
knives.
-Q7271

-Q7271

Power part cabinet doors are interlocked

with the safety grounding switch.
DC+

L_P

NP

DC-

L_N

ACS 5000 Training -RevC2

ABB Ltd - 19 -

-Q7271
-Q7271
PE

Because in ACS 5000 there are three physical GND switches, there are in
total three feedback signals available from the GND switches. This means
three GND switch closed and three GND switch open status signals.
GND switch status signals are connected in series both for the open and
closed status. Drive status GND switch closed is reached only if all three
GND switches are closed. Drive status GND switch open is reached only
if all three GND switches are open.
If trying to ground the drive, all three GND switches need to be closed
before drive is physically grounded. If one or two of the GND switches are
not closed, drive grounded status will not be reached.

If trying to open the closed GND switches, all three switches need to be
opened before drive not grounded status will be reached. If only one or
two GND switches are opened, application SW will be in DCGround
unknown status. DCGround unknown

GND switch 1 GND switch 2 GND switch 3 Drive grounding status

0
0
0
not grounded
1
0
0
unknown
0
1
0
unknown
0
0
1
unknown
1
1
0
unknown
1
0
1
unknown
0
1
1
unknown
1
1
1
grounded

ABB Ltd

GND switch open = 0

GND switch closed = 1

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ACS 5000 Training

Power part

Hard coupled DC link

Directly connected to the DC bus bars. DC

The hard and soft coupled DC link smoothes the intermediate DC voltage
and decouples the rectifier from inverter.

-C72502/U

ACS 5000 Training -RevC2

ABB Ltd - 21 -

-C72501/U

Hard and soft coupled capacitor bank are located in the right side of each
phase module.

C7250
1

C7250
2

Rectifier / inverter
stack

Hard and soft coupled

capacitors

ABB Ltd

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ACS 5000 Training

Power part

Inverter phase module (H-bridge)

The inverter unit inverts the DC voltage to the AC motor voltage.

The inverter allows four-quadrant operation.
It is a 5-level Voltage Source Inverter.

One inverter unit for each phase:

One 3-level inverter cell to each motor
phase 3
One 3-level inverter cell to a Common
Rail CR (star point) of all phases

ACS 5000 Training -RevC2

ABB Ltd - 22 -

3CR

2 x 3-level inverter cells (H-bridge)

23

To the motor
phase (MPh)

To the star point / common rail (CR)

ABB Ltd

Page 22

ACS 5000 Training

Power part

Inverter phase module

Clamping
capacitor

RC-IGCT

ACS 5000 Training -RevC2

ABB Ltd - 23 -

NP diode
NP

ABB Ltd

Balancing
resistor

Clamping
diode

Page 23

ACS 5000 Training

Power part

Integrated Gate Commutated Thyristor

ACS 5000 Training -RevC2

ABB Ltd - 27 -

INU IGCTs free wheeling diode is integrated with RC-IGCT

ABB Ltd

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ACS 5000 Training

Power part

Inverter operation: 3-level inverter cell

DC(+)

Two IGCTs are turned ON at a time:

IGCT

1
NPD1
VDC

NPD2

Output (CR or
motor phase)

ACS 5000 Training -RevC2

ABB Ltd - 29 -

Output
connected to

Current path:

1+2

DC+

1+2

2+3

NP

NPD1+2 or

3
4

ABB Ltd

IGCTs
ON

NP

3+NPD2
3+4

DC-

3+4

DC(-)

Page 29

ACS 5000 Training

Power part

Inverter operation: 5-level switching topology

DC(+)
V21

V11

V22

V12

VDC
2
NP

VDC

CR

Motor

MPh

NP

phase
output

VDC

V23

V13

V24

V14

ACS 5000 Training -RevC2

ABB Ltd - 30 -

DC(-)
CR
(Inverter star point)

Phase to CR voltages:

Voltage levels

VMPh-CR

MPh

CR

VMPh-C

Vectors

+VDC/2

+VDC/2

+VDC

+2

+2

-VDC/2

-1

-1

-VDC/2

VDC

-2

-2

0
0

+1

+1

Please note the redundancy for:

ABB Ltd

vectors 0 (three combinations)

+1 and -1 (two combinations)

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ACS 5000 Training

Power part

Inverter operation: 9-level output to the motor

VL1-L2 = VL1-CR + VCR-L2
VL1-L2 = VL1-CR VL2-CR

VDC
2

L1

VDC
VDC
2

CR
VDC
2

L2

VDC
ACS 5000 Training -RevC2
ABB Ltd - 31 -

VDC
2

Combining the 5 levels for motor phase and CR for each phase,
phase to phase voltages will have the values:
Note: Switching vectors L1 and L2 as in the previous page.

Vector

Voltage

Vector Voltage

Voltage

L1

L1-CR

L2

L2-CR

L1 - L2

+2

VDC

-2

-VDC

2 x VDC

+2

VDC

-1

-1/2 x VDC

3/2 x VDC

+2

VDC

VDC

+1

1/2 x VDC

1/2 x VDC

-1

-1/2 x VDC

-1/2 x VDC

-2

-VDC

-VDC

-2

-VDC

-1

-1/2 x VDC

-3/2 x VDC

-2

-VDC

+2

VDC

-2 x VDC

With, of course, a lot of redundancies:

(+2)&(-1) == (+1)&(-2), (+2)&(0) == (+1)&(-1) == (0)&(-2), etc.

ABB Ltd

Page 31

ACS 5000 Training

Power part

Output wave forms

Torque

Line to line voltage

ACS 5000 Training -RevC2

ABB Ltd - 32 -

Current

ABB Ltd

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ACS 5000 Training

Power part

How to reach the 6.9 kV

Creating one line to line motor voltage

ACS 5000 Training -RevC2

ABB Ltd - 33 -

MOTOR

ABB Ltd

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ACS 5000 Training

How to reach the 6.9 kV

ACS 5000 Training -RevC2

ABB Ltd - 34 -

Power part

Current flow according to principle above:

MOTOR

ABB Ltd

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ACS 5000 Training

How to reach the 6.9 kV

ACS 5000 Training -RevC2

ABB Ltd - 35 -

Power part

Current flow according to principle above:

MOTOR

ABB Ltd

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ACS 5000 Training

How to reach the 6.9 kV

ACS 5000 Training -RevC2

ABB Ltd - 36 -

Power part

Current flow according to principle above:

MOTOR

ABB Ltd

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ACS 5000 Training

How to reach the 6.9 kV

ACS 5000 Training -RevC2

ABB Ltd - 37 -

Power part

Current flow according to principle above:

MOTOR

ABB Ltd

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ACS 5000 Training

How to reach the 6.9 kV

ACS 5000 Training -RevC2

ABB Ltd - 38 -

Power part

Current flow according to principle above:

MOTOR

ABB Ltd

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ACS 5000 Training

Power part

How to reach the 6.9 kV

The line to line voltage at basic switching

motor line to line voltage

10000 V
5000 V
time

ACS 5000 Training -RevC2

ABB Ltd - 39 -

-5000 V

ABB Ltd

-10000 V

Page 39

ACS 5000 Training

Output voltage waveforms

ACS 5000 Training -RevC2

ABB Ltd - 40 -

Power part

ABB Ltd

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ACS 5000 Training

Output current waveforms

ACS 5000 Training -RevC2

ABB Ltd - 41 -

Power part

ABB Ltd

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ACS 5000 Training

Power part

Control HW in the phase module

=COU

AMC board
=INU 1_3

Phase INT board

PEC-INT board

IPS

IPS

CVMI
HVD

VLSCD

To next phase INT

board

DC

AC
ACS 5000 Training -RevC2
ABB Ltd - 43 -

EAF

AC

DC
VLSCD

To next phase INT

board

The main control equipment is installed in the Control Cabinet (control

boards AMC33 / AMC34, main modulator PEC-INT, I/O modules, etc.)
The main modulator PEC-INT is the interface between the control
board (AMC3x) and the three phase interface boards INT, one in each
phase module.
Control and protection boards are also installed in each phase module
Phase Interface board INT

Current and Voltage Measuring Interface CVMI

High Voltage Divider HVD

Earth Fault board, EAF, used as diode failure detection

equipment
EAF

Note: A fourth EAF board is located in the Terminal Unit (TEU), behind
the swing frame of the control cabinet. This board is used for ground
fault monitoring.

ABB Ltd

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ACS 5000 Training

Power part

Control HW
+A21
+A22
+A23

ACS 5000 Training -RevC2

ABB Ltd - 44 -

HVD

INT

COU / TEU

EAF, ground fault monitoring

-A9001, in +A15
ABB Ltd

EAF

(as diode failure

detection)

Voltage
sub-print

CVMI

Phase modules

EAF as diode failure detection

-A7221 in +A21 - +A23

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ACS 5000 Training

Power part

Interface board (INT)

Interface board (INT) serving as a
communication interface to the control
system in the COU.
The pulse firing logic for the IGCTs and fast
protection functions are integrated on the
board as well.

ACS 5000 Training -RevC2

ABB Ltd - 45 -

Fiber optic cables are used for transmission

of data between the interface board and the
control system and for the gate firing signals
of the IGCTs.
INTIGCT

ABB Ltd

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ACS 5000 Training

Power part

Interface board (INT)

IOC from CVMI
PWF IPS1
PWF IPS2

RC-IGCT firing

VLSCD (DC+)
VLSCD (DC-)
FT-Loop (DC+)
FT-Loop (DC-)

Link_D

PPCS Channels:

ACS 5000 Training -RevC2

ABB Ltd - 48 -

CVMI communication

ABB Ltd

Link_C
Link_B
PEC-INT communication
FT link

Link_A
Aux power supply

Page 48

ACS 5000 Training

Power part

Interface board (INT)

INT board diagnostics: Indication LEDs

ACS 5000 Training -RevC2

ABB Ltd - 51 -

2 green LEDs (V103, V113)

for POWER OK. If they
are on, the internal +5V DC
supply voltages are
within the allowed limits.

ABB Ltd

8 yellow LEDs (V561V568) for testing the

firmware in EPLD (firmware specific)

1 yellow LED CONFIG. FAULT

near the EPLD circuit. LED is on
during EPLD configuration

Page 51

ACS 5000 Training

Power part

Short circuit detection

In parallel to every INU di/dt choke a Voltage Level Short Circuit Detection
(VLSCD) board is installed. The VLSCD board is a passive board, which detects the
voltage appearing across the di/dt chokes during the commutation of the IGCTs.
During this time a fiber optic signal is sent to control (Phase INT board).
VLSCD
VLSCD

AC

+DC
+DC

NPNP

Phase

PHASE

INT
next phase

DC

-DC
-DC
VLSCD
VLSCD

Phase INT

ACS 5000 Training -RevC2

ABB Ltd - 55 -

VLSCD

di/dt+

di/dt-

VLSCD is a pure analogue device which performs short circuit detection

through the supervision of the voltage on the di/dt chokes (Ls1, Ls2).
Each time when one of the IGCTs of the upper side is turned on there is
a voltage on the Vls1 choke equal to the positive DC bus voltage
during the commutation time and each time when one of the IGCTs
of the lower side is turned on there is a voltage on the Vls2 choke equal
to the negative DC bus voltage during the commutation time.
If this voltage remains more than a certain allowable time (6 10 s), a
short circuit has occurred. The supervision of this signal is made in
the INT board and the supervision time is programmed in the
EPLD.
If signal does not appear every 50 ms, when inverter operates with
sufficient load current
VLSCD fault detection
Optical output signal lights more or less at the same frequency as
inverter switching frequency.
VLSCD is connected to high voltage!

ABB Ltd

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ACS 5000 Training

Power part

/EAF

Rectifier supervision / EAF board

ACS 5000 Training -RevC2

ABB Ltd - 61 -

If measured voltage is above defined limit, the optical output signal

of EAF board turns OFF and the PEC-INT board in COU detects a
rectifier diode failure.

The only setting element on the board is the DIL switch. The selectable
detection levels are (the voltage over Rn):

Switch setting

1
OFF
OFF
OFF
ON

2
OFF
OFF
ON
OFF

3
OFF
ON
OFF
OFF

Switching
threshold
4
ON
OFF
OFF
OFF

500 V
660 V
825 V
1150 V

Check right settings from project related electrical diagrams.

ABB Ltd

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ACS 5000 Training

Power part

Cooling

The air cooling unit feeds the cooling air to the main power
components and transfers the heat out of the cubicle.
Standard converter cooling fan:
3.5 MVA 2 fans

ACS 5000 Training -RevC2

ABB Ltd - 62 -

7.0 MVA 3 fans

ABB Ltd

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ACS 5000 Training

Power part

Cooling fan control

ACS 5000 Training -RevC2

ABB Ltd - 63 -

The converter activates the cooling fans when charging the DC link.
After a certain delay it begins to sample the air supervision. After a
MCB off command the cooling fans run for a defined cooling down
time.

ABB Ltd

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ACS 5000 Training -RevC2

ABB Ltd - 64 -

ACS 5000 Training

ABB Ltd

Page 64