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Medium Voltage Drives

ACS 1000 product overview


A general purpose drive and beyond
Steven Husein,
steven.husein@id.abb.com

© ABB Group
April 23, 2015 | Slide 1
ACS 1000 product overview and update

§ Overview

§ ACS 1000 Air Cooled

§ ACS 1000i (with integrated


transformer)

§ ACS 1000 Water Cooled

§ ACS 1000 Core Features


and Options

© ABB Group
April 23, 2015 | Slide 2
ACS 1000 product portfolio

(6’000 kVA)
5,000 W3
Motor Power in

Water-
W2 cooled
re-connection with
W1 of Motor step- up
kW

2’000 A3 Air- cooled


winding from
Star to Delta
transformer

A2

315 A1

6.0 6.9 8.0 13.8


2.3 3.3 4.0
Motor Voltage in
kV

§ Available Output Voltage and Power Range

© ABB Group
April 23, 2015 | Slide 3
Applications
Grinding mills, conveyors, fans and
Cement, Mining and Minerals pumps,

Chemical, Oil and Gas Compressors, extruders and pumps

Marine Pumps,

Metals blast furnace blowers, fans and pumps

Pulp and Paper Fans and pumps

Gas turbine starters, ID / FD fans and


Power Generation pumps

Water and Waste Water Pumps

Other Applications Test stands and wind tunnels


ACS1000 product overview

§ Drive Product with a wide variety of


Standard Options
§ Less than 2 days commissioning
for the drive
§ Square Torque or Constant Torque
applications, e.g.:
§ Pumps, fans, compressors,
conveyors, extruders, mixers
etc.
§ 1 or 2 Quadrant operation
§ for Asynchronous motor control
§ Sinusoidal output
§ Efficiency >98%
§ IGCT technology
§ Direct Torque Control

© ABB Group
April 23, 2015 | Slide 5
ACS 1000 three-level voltage source inverter (VSI)

ACS 1000 MV Variable Frequency Drive


Main Feeder Rectifier DC-Link & Inverter Output Sine
MV Converter Input Prot IGCTs Filter
Breaker
Supply Transformer
& Protection

I>> Prot

MV AC
Induction
Motor

Supply Side DC Link and Inverter Sine Wave


Protection IGCTs Output Filter

§ Main Circuit Breaker, 12 pulse Transformer and Diode Rectifier stage


§ Fuse less Design, using Protection IGCTs
§ DC Link, DC Capacitors and Common Mode Choke (Option)
§ Three-level Voltage Source Inverter (VSI) equipped with IGCTs
§ Output sine wave filter

© ABB Group
April 23, 2015 | Slide 6
ACS 1000 main features

Supply Side Medium Voltage Medium Voltage


Supply Bus Supply Bus

Main Feeder Main Feeder


I>> Prot I>> Prot
Breaker Breaker
& Protection & Protection

12-pulse 24-pulse
Converter Input Converter Input
Transformer Transformer

Rectifier
Rectifier

§ Standard: 12 pulse- transformer and diode bridge


§ Option: 24 pulse- transformer and diode bridge
§ Converter transformer type: Oil- or dry type

é Conformity to IEEE 519/1992


é Total power factor: 0.95 constant over speed range
é Transformer can be placed inside the building or
outdoor
© ABB Group
April 23, 2015 | Slide 7
ACS 1000 Topology

§ 12-Pulse rectifier (standard)


§ 24-Pulse rectifier (optional)
ACS 1000i Topology

§ Integrated transformer and input contactor


§ On-board auxiliary power supply
§ 24-Pulse rectifier (Standard)
Rectifier
n ACS 1000 is based on the three-level
voltage source inverter technology with a 12
pulses (24 pulses as an option) input rectifier
n ACS1000i is equipped with a 24-Pulse
diode rectifier
DC-Link
§ Fuseless Design

Protection IGCTs are


placed between rectifier
and DC-link capacitors ACS 1000 Converter with Protection IGCTs
à more than 100 times
faster than conventional
fuses
à only two protection
IGCTs instead of 12
fuses
§ Fuses are known
to be costly,
unreliable, subject
to aging

Faster and better protection than


medium voltage power fuses
ACS 1000 main features

ACS 1000 MV Variable Frequency Drive


Main Feeder Rectifier DC-Link & Inverter Output Sine
MV Converter Input Prot IGCTs Filter
Breaker
Supply Transformer
& Protection

I>> Prot
MV AC
Induction
Motor

§ Fuse less Design


§ To protect the system against unnecessary damage
§ Protection IGCTs are placed between rectifier and DC-link
capacitors – more than 100 times faster than conventional
fuses
§ Fuses are known to be costly, unreliable, subject to aging

© ABB Group
April 23, 2015 | Slide 12
Inverter

§ Each leg of the 3-phase inverter bridge consists


of a combination of 4 IGCTs with 2 neutral
diodes for 3-level switching operation.

§3-level § Voltage Source Inverter (VSI)

§Sine Wave
§Filter

§Standard
§DC
§AC Induction
§Link
§Motor

§Legend

§IGCT
§ with integrated gate driver and
§freeweeling diode
§NPC Diode§(Neutral Clamping Diode)
ACS 1000 IGCT technology
Product
IGCT: Integrated Gate Commutated Thyristor

§ IGCT delivers the benefits of IGBT’s


with the added robustness required
for MV drive applications.

§ Conducts like a thyristor

§ Switches like a transistor

§ Low on-state and switching losses

§ high reliability, high efficiency, low


parts count

© ABB Group
April 23, 2015 | Slide 14
ACS 1000 inverter switching patterns
§ Positive Current:

§GU
§ Negative Current:
ACS 1000 3-Level inverter output voltage

§ Phase to Phase Inverter Output Voltage


§ Five voltage levels (phase to phase) due to 3-level inverter
topology

© ABB Group
April 23, 2015 | Slide 16
Output sine filter

Output Sine Filter

Inverter Motor
Side Side

§Inverter output voltage §Drive output voltage to the


motor
Compatibility with new and existing motors

§ Output Sine Filter

Inverter Motor
Side Side

Inverter output voltage Drive output voltage to the


motor

§ Output sine filter


§ Is used in all ACS1000 Family Drives as a standard
§ Actively controlled LC low pass filter
§ Eliminates virtually all inverter switching harmonics
to the motor
§ Keeps motor and bearings common mode voltage
free
© ABB Group
April 23, 2015 | Slide 18
Compatibility with new and existing motors

Output sine filter


§ Motor voltage and current waveforms
§ Sinusoidal output waveforms throughout the full
operating range
§ THD of current and voltage typically below 2%, i.e. far
better than required by most stringent network
harmonic standards
© ABB Group
April 23, 2015 | Slide 19
Compatibility with new and existing motors

§ Output sine filter


§ Motor efficiency as under DOL operation
no motor de-rating required
§ No voltage reflections, no common modes
saves motor insulation and bearings
§ No high frequency components
use of standard cables
no limitation of cable length
no EMC problems
§ No switching harmonics
no additional motor noise

© ABB Group
April 23, 2015 | Slide 20
Main data – DC-Link capacitors

Self healing:
If a dielectric breakdown between capacitor foils occurs the
energy, released by the arc discharge in the breakdown
channel, is sufficient to totally evaporate the thin metal coating
in the vicinity of the channel. The rapid expansion of the
plasma in the breakdown channel causes it to cool after a few
microseconds, thus quenching the discharge. The insulated
region thus resulting around the former faulty area will cause
the capacitor to regain its full operation ability.

Lowest lifetime costs !


or continue

§ Long-life capacitors
§ Advanced, environmental friendly, natural oil-filled foil capacitors
have a substantially longer lifetime than electrolytic capacitors
§ ‘State of the art’ technology, highly reliable, also used in heavy duty
applications, such as railway traction systems
§ Self healing !

© ABB Group
April 23, 2015 | Slide 21
Reliability of DC-link capacitors

§ Lifetime expectancy
§ under nominal conditions (i.e. 40°C
ambient) > 15 year
§ under typical operating conditions
(30° C ambient) > 20 years
§ ABB recommends preventive
replacement after 12 years
of operation in order to maintain a
high product
availability (AC and DC power
capacitors)
§ virtually no aging during storage, no
“formatting”
(like for electrolytic caps) required

© ABB Group
April 23, 2015 | Slide 22
ACS 1000 Performance
0.4 – 6.0 MVA applications

© ABB Group
April 23, 2015 | Slide 23
Performance

§ Direct Torque Control (DTC)


§ Powerful control platform
§ Power loss ride-through
§ Ride-through capability for supply voltage dips down to zero
§ Flying start and automatic restart
§ Catches a spinning load and smoothly takes it back to set speed
§ Flux optimization
§ Reduction of motor losses under part load operation
§ Critical speed avoidance bands
§ Skips operation at critical speeds
Performance
§ Direct Torque Control
§ Provides fast, accurate and stepless control
from zero to full speed
§ Full torque with optimal speed accuracy over the whole speed range
§ Negligibly low torque ripple
§ Minimal inverter switching losses at maximal control performance
§ No speed encoders needed

§Typicaltorque response (t) of a DTC drive,


compared with flux vector control and
open loop pulse width modulation (PWM)
Ride through capabilities
§ Main power loss ride through n Auxiliary power loss ride
through
Aux. power loss ride through
§ Trigger of function:
§ Loss of 3 phase supply, or
§ Reduction of voltage of 3 phase supply by 20% to 25% percent (depending on the capabilities of
the aux. power supply modules from Phoenix)
§ Functionality
§ Internal batteries or 1 phase supply (safeline) will keep control fully operational
§ Cooling will stop (fan and pump) à can be tolerated for short time
§ Power has to return within specifc ride through time (otherwise “aux. power loss”-trip):
§ ACS 1000 Air cooled 5 sec
§ ACS 1000 integrated 5 sec
§ ACS 1000 Water cooled 1 sec (5 sec if main power and aux. power fail at the same time)
§ During aux power ride through: no change in the operation of the drive.
§ In case of “aux. power loss”-trip, modulation will stop, protective functions remain in operation
§ After an "aux. power loss"-trip, the drive will automatically accelerate again to reference speed, if
the automatic start function is enabled. The automatic restart is limited to max. 600sec (default:
30sec).
§ In case aux. power does not return and drive has internal batteries, control will be switched off after
about 15 min.
§ Within the 5 sec limit and in case of a simultaneously fail of aux. and main power the drive will be
automatically accelerate again to reference speed 2 seconds after the (both) voltages have
returned.
Supply side

§ Supply Voltage Variation


§ +/- 10%,
§ down to –25% possible
§ current limiter may reduce power
§ Aux. power supply must remain within its limits (+/-
10%)
§ max. 2% unsymmetry

§ Aux. Supply (3-Phase)


§ 400 V / 50 and 60 Hz,
§ 480 V and 575 V / 60 Hz
§ 690V / 50 Hz / 60 Hz
§ +/- 10%
© ABB Group
April 23, 2015 | Slide 28
ACS 1000 core features
Special functions

§ Scalar Control
§ Basic control method for different functionalities:
§ Step-up transformer (and synchronised bypass)
§ Connection of more than one motor to one
converter
§ Control of ”very” long cables: 5 ... 20km

§ Long Motor Cables


§ Cable model for DTC enables cable length up to 5km
§ Cable model for scalar control enables cable length up
to a voltage drop of 20%

© ABB Group
April 23, 2015 | Slide 29
Water cooled drives
2000 - 5000kW applications

© ABB Group
April 23, 2015 | Slide 30
ACS 1000 water cooled

Water Cooled
Range: 4200 mm for W1 frame size
2.7 - 6 MVA; 4700 mm for W2 and W3 frame size
3.3 and 4kV;

2000 mm

900 mm

© ABB Group
April 23, 2015 | Slide 31
ACS 1000 water cooled

Rectifier and Inverter

Cooling
Sine Filter and Unit
Sine Filter DC Capacitors
Control Choke

© ABB Group
April 23, 2015 | Slide 32
ACS 1000 water cooled
1.8 – 5 MW Inverter stacks on
swing frame for easy
accessibility
Application &
motor control
board with
fast digital
signal processor
and DTC

Water cooling

Output filter for


smooth sinusoidal
current and voltage
waveform IGCT power semiconductors
(behind swing frame)

© ABB Group
April 23, 2015 | Slide 33
3BHT490557R0001 Rev. A
ACS 1000 water cooled
Older Pink swing frame

© ABB Group
April 23, 2015 | Slide 34
ACS 1000 water cooled
Swing frame

© ABB Group
April 23, 2015 | Slide 35
ACS 1000 water cooled
Cooling circuit overview

© ABB Group
April 23, 2015 | Slide 36
ACS 1000 options common mode choke

§ This option is needed if cable length between converter


transformer and ACS 1000 exceeds following limits:
§ 30 m for ACS 1000, 12-pulse and
§ 20 m for ACS 1000, 24-pulse.
§ If cables are longer than following limits, then please contact
PRU:
§ 200 m for ACS 1000, 12-pulse and
§ 150 m for ACS 1000, 24-pulse.
© ABB Group
April 23, 2015 | Slide 37
Additional features

§ Long Motor Cables


§ Cable model for DTC enables cable length up to 5km
§ Cable model for scalar control enables cable length up
to a voltage drop of 20%
§ Cable entry
§ Top or bottom
§ Protection Classes (available as options)
§ Air Cooled Converters: IP21, IP22, IP32, IP42
§ Water Cooled Converters: IP31, IP54
ACS 1000 options redundant cooling fan
Air cooled drives

Dimensions: 2000mm wide, 800mm high


Noise Level: <85 dB (A)

Attention: 7.5% Power derating required!

© ABB Group
April 23, 2015 | Slide 39
ACS 1000 air-cooled
redundant fan, noise damper, 75 dB

© ABB Group
April 23, 2015 | Slide 40
3BHT490557R0001 Rev. A
ACS 1000 options
Redundant cooling fan

§ Water Cooled Drives


Fan 2 § The redundant fan is
placed on top of the
drive’s water cooling
unit
§ Height about 30cm
Fan 1 (however 1m
clearance needed for
exchanging the fan)
§ No power derating
required
§ Only available in
combination with
Redundant Cooling
Pumps

© ABB Group
April 23, 2015 | Slide 41
Braking chopper
Mechanical layout

644 mm wide
cabinet, installed
on the right hand
side of the drive

© ABB Group
April 23, 2015 | Slide 42
ACS 1000 water cooling engineered options

Special Water Cooling


Options
§ Flange connections
(instead of standard hose
connectors)
§ ANSI flange 2’’ / B16.5 /
150 lbs or
DN 50 / PN16
§ Flange orientation to
top, bottom or side
§ Manual shut-off valves
on request
§ 2’’ ANSI flange also for
drain connection
available

© ABB Group
April 23, 2015 | Slide 43
ACS 1000 water cooling engineered options
ACS 1000-W standard
W/W HEX

Filter Cooling raw


Q P T water supply
L open § analog
§ analog
§ analog from
system customer side
L
§ digital > 4°C,
Power losses water W/W HEX
< 27 °C (38°C)

by
fin/fan cooler,
§ analog
chillers or
Advantages: others

§ Separation between internal demine§ water


M and external
raw water circuit
§ Lowest WCU costs on ACS1000 side

Power losses Air A/W HEX

© ABB Group
April 23, 2015 | Slide 44
ACS 1000 water cooling engineered options

ACS1000-W One-
loop system < 38°C Heater*
water temp. Filter
Q P T *Heater needed if
closed § analog
§ analog
§ analog
Watercan be below
5°C during Standby
system Customer
side
Power losses water W/W HEX,
Advantages: fin/fan cooler
or chiller
§ No raw water pumps needed <38°C

§ No temperature control valve on raw water side needed, i.e.


minus temperatures
§ P possible by simply adding glycol (derating
§ M
!) § analog

§ A/W HEX

Power losses Air

© ABB Group
April 23, 2015 | Slide 45
Example for external W/W HEX

Raw water inlet § External W/W HEX


§ Tailored for different
requirements
§ Titanium version for
seawater cooling
§ Design for heavily
Raw water outlet
polluted raw water
possible
§ Even tube HEX
could be used
§ Also redundant
Manual shut-off valve HEX’s possible on
request

© ABB Group
April 23, 2015 | Slide 46
ACS 1000 water cooling engineered options

ACS1000-W One-
loop system < 45°C
water temp. § Filter Heater*
Q P T *Heater Customer
§ closed needed if
§ analog
§ analog
§ analog Watercan be side
§ system below 5°C water / water
during
Standby HEX
§ Power losses water
Advantages: or fin/fan
cooler
<38°C
§ No raw water pumps needed
up to 45°C
§ No temperature control valve on raw water side needed, i.e. with derating
minus temperatures possible by simply adding glycol (derating
!) § P § M
§ analog

§ Increased water temperatures up to 45°C possible à no need


§ Filter
for chiller, if max. ambient temperature below 40°C
§ A/W HEX
Autonomous
compact
§ Power losses Air §§ DP
§ Digital chiller (7kW)

< 27 °C water
temperature

© ABB Group
April 23, 2015 | Slide 47
Example for 7kW compact chiller

Air Outlet

Chilled Water
Inlet

Chilled Water
Air Inlet Outlet

Frontview Rearview

© ABB Group
April 23, 2015 | Slide 48
ACS 1000 water cooling engineered options

ACS1000-W One-
loop system, called
“IP42” Filter Heater*
Q P T *Heater Customer
closed needed if
analog § analog
§ analog Watercan be side
system below 5°C water / water
during
Standby HEX
§ Power losses water or fin/fan
Advantages: cooler
<38°C
§ No raw water pumps and no A/W HEX needed up to 45°C
with derating
§ Increased water temperatures up to 45°C
P M
§ feasible up to 40°C max. ambient room temperature
analog
(power
derating above 35°C room temperature) Cooling Air from
control room

§ Power losses Air

up to 7kW heat
losses into the
control room

© ABB Group
April 23, 2015 | Slide 49
Example for IP42 Cabinet

Air Outlet

Air Inlet
Air Inlet
Air Inlet
Air Inlet

© ABB Group
April 23, 2015 | Slide 50
ACS 1000 options
Split cabinet
§ Only available for
water cooled
drives
§ For ease of
transportation into
narrow buildings
§ Engineered
Option
§ Contact PRU for
quotation

© ABB Group
April 23, 2015 | Slide 51
24x365 Service support

Service Level

1 Field Engineer Customer / Plant


Local & Regional
Service
Local SupportLine

Centrally based Support


SupportLine

4 Product Appl. R&D


R&D

© ABB Group
April 23, 2015 | Slide 52
ACS1000 service concept

Service Escalation
Level 4 (R&D Resources in Turgi, Switzerland)
Engineering Design Resources
If the problem is not resolved by level 3, the call
is routed to the product development center,
the highest level of service support

24x365 SupportLine
Level 3
If also local efforts fail, a Support Center Experts of ACS1000 available in
operator can be called. A system specialist Turgi, Switzerland
will return the call in 30 minutes. - Emergency Spare Parts Deliveries out of
Logistic Center Helsinki / Finland

Local SupportLine Level 2


If the field engineer does not solve the
problem in two hours, he contacts Local experts
the local specialist.

Local Field Service Level 1


Whenever a problem arises, customer can
call the field engineer for assistance. Local Field Service Engineers

© ABB Group
April 23, 2015 | Slide 53
© ABB Group
April 23, 2015 | Slide 54