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ACS 2000
General Purpose MV Drive
3.3KV – 6KV Steven Husein,
steven.husein@id.abb.com
© ABB Group.
April 23, 2015 | Slide 1
MVD-EOIP02-EN
ACS 2000
Agenda
© ABB Inc.
April 23, 2015 | Slide 2
Medium Voltage Drives
For industries including…
Special applications,
Power Pulp & Paper Water
such as wind tunnels
© ABB Inc.
April 23, 2015 | Slide 3
Medium Voltage Drives
For applications such as…
MV Drive
Network
compatible Motor Compatible
Harmonic Minimize V/I Stress
Compliance
It is how this is
accomplished that
differentiates solutions
© ABB Group
April 23, 2015 | Slide 6
© ABB Inc.
April 23, 2015 | Slide 7
Medium Voltage Drives
ACS 2000
Cooling: air
Power range 300 – 3000 HP
Output voltage: 4.0 kV – 4.16 kV
Available for: direct-to-line connection
Cooling: air
Power range: 250 – 2,240 kW
Output voltage: 6.0 – 6.9 kV
Available for: direct-to-line connection
connection to a separate two
winding transformer
with an integrated transformer
© ABB Inc.
April 23, 2015 | Slide 8
ACS 2000
Industries and Applications
Industries Applications
Water Pumps
© ABB Group
April 23, 2015 | Slide 9
ACS 2000
Simple and Reliable Motor Control
Output Output
Design Standards Configuration
Voltage Rating (ND)
Direct to Line
300-3000hp NEMA, IEEE, cUL
4-4.16 kV External Trafo
(224-2300kW) IEC, EN, CE
External Trafo
3.3kV, 250-2240kW Internal Trafo
IEC, EN, CE
6-6.9kV (335-3000hp) Direct to Line
© ABB Group
April 23, 2015 | Slide 10
ACS 2000
Configurations Shipping Today: 3.3kV, 6kV
ACS 20xx
3.3 – 6.9kV
up to 2MVA
direct-to-line
AFE
© ABB Group
April 23, 2015 | Slide 11
General Purpose Drive
Splash Screen
Maximal Flexibility Key Features
direct-to-line (DTL)
– simplicity – 3in3out – trsp costs
integrated transformer
voltage matching – galvanic 3MVA
isolation – simplicity – 3in3out
external transformer
voltage matching – heat & footprint
in el. room – galvanic isolation
2MVA
direct-to-line (DTL)
– simplicity – 3in3out – trsp costs
integrated transformer
voltage matching – galvanic
isolation – simplicity – 3in3out 1MVA
external transformer
voltage matching – heat & footprint
in el. room – galvanic isolation
6kV
4kV
1 1
3.3kV, 6 kV 4 kV
1 Basic Motor Service Voltage Class
2 Unique Selling Preposition: World‘s first transformerless Voltage Source Inverter / PF 1
ACS 2000
General Purpose Medium Voltage Drive
Inverter
Line Side Compliance LV Control section Unit (INU)
• IEEE 519, IEC 61000-2-4, Class 2 Compliant
• Simple system integration
• Networks up to 45kA Short Circuit(500MVA for 6.660kV)
• Suitable for Solid, Resistive, and Floating Networks
• Common Mode mitigation built in
Transformerless Configuration
§ Braking Energy Recovery
Removable
§ Dynamic Compensation of Network Voltage Interchangeable
Fluctuations up to 30% Dip phase modules
§ “3 in 3 out” cabling minimizes installation time and Top and bottom Active Front End (AFE)
cost entry, for line/load
and control power
© ABB Group
connections
April 23, 2015 | Slide 13
ACS 2000
General Purpose Medium Voltage Drive
Inverter
Machine Friendly Operation LV Control section Unit (INU)
§ 5 Level Topology
§ Optimized filtering and silicon
§ Maximize reliability while minimizing size , weight
and complexity
Modular Construction
§ Serviceable from Front
§ One Phase Module spare for each frame
§ Industry Leading Mean Time To Repair (MTTR)
provides high availability and low maintenance Removable
costs Interchangeable
§ Supports OEM repackaging phase modules
Top and bottom Active Front End (AFE)
entry, for line/load
and control power
© ABB Group
connections
April 23, 2015 | Slide 14
ACS 2000
General Purpose Medium Voltage Drive
Inverter
Direct Torque Control (DTC) LV Control section Unit (INU)
§ Provides fast, accurate and stepless control
from zero to full speed
§ Power ride through during supply voltage dips
Air Cooled
§ High reliability
§ Easy to apply
© ABB Group
April 23, 2015 | Slide 16
ACS 2000 Factory
Production Facility
Helsinki, Finland
AC Drives
New Berlin WI,
USA Turgi, Switzerland
MV Drives PG Krakow,
Poland
Beijing,
China
Bangalore,
4160V Markets India
LV Control Inverter
Swing Frame Phase Modules
DC Link Cap
and ground switch
© ABB Group
April 23, 2015 | Slide 18 Input filter
unit
Mechanical Design
ACS 2000 phase module
Phase interface
control board
Connectors
© ABB Group
April 23, 2015 | Slide 19
Mechanical Design
ACS 2000 phase module
Phase capacitor
Gate units
Low inductive
busbar
Integrated current
sensor
IGBT modules
© ABB Group
May 24, 2013 | Slide 20
Power Topology
General topology facts
© ABB Group
April 23, 2015 | Slide 21
Power Topology
General topology facts
© ABB Group
April 23, 2015 | Slide 23
ACS 2000
Installation options
Classic configuration with Direct-to-line (DTL) connections
transformers
Main power supply
Transformer
ACS 2000
Motor ~ ~ ~ ~ ~ ~
© ABB Group
April 23, 2015 | Slide 24
external integrated single DTL several direct-to-line drives on
transformer transformer a common AC bus
System Configurations
External Transformer
© ABB Inc.
April 23, 2015 | Slide 25
System Configurations
Direct-to-Line
© ABB Group
April 23, 2015 | Slide 26
System Configurations
Diode Front End Integrated Transformer
© ABB Inc.
April 23, 2015 | Slide 27
ACS 2000 Direct to Line
Block Diagram
© ABB Group
April 23, 2015 | Slide 28
ACS 2000 External Transformer
Block Diagram
© ABB Group
April 23, 2015 | Slide 29
ACS 2000 Integrated transformer
Block Diagram
© ABB Group
April 23, 2015 | Slide 30
Expanded Scope of Supply
Integrated MV Switchgear Configuration
Manual no-load
disconnect switch
with access window
Base converter
(Frame 1, 2 or 3)
Custom controls
© ABB Group
April 23, 2015 | Slide 31
Expanded Scope of Supply
Integrated MV Switchgear Configuration
§ Standard configuration
§ Vacuum contactor (7.2 kV, 400 A)
§ No load disconnect switch
§ Optional configuration
§ Control power transformer
§ Motor monitor relay
§ Custom controls
© ABB Group
April 23, 2015 | Slide 32
§Typical LV-IGBT circuit
IGBTs: 360
Diodes: 108
Power Fuses: 54 M
MV-IGBT circuit
MP
§IGBTs 36 pcs
§FW Diodes36 pcs M
© ABB Group
April 23, 2015 | Slide 35
ABB Topology
From 3-level to 5-level topology
© ABB Group
April 23, 2015 | Slide 36
Topology
From 3-level to 5-level topology
© ABB Group
April 23, 2015 | Slide 37
Topology
Phase to ground voltage levels
VPH
+VDC
+VDC/2
NP
-VDC/2
-VDC
© ABB Group
April 23, 2015 | Slide 38
Topology
Phase to ground voltage levels
VPH
+VDC
+VDC/2
NP
-VDC/2
-VDC
© ABB Group
April 23, 2015 | Slide 39
Topology
Phase to ground voltage levels
VPH
+VDC
+VDC/2
NP
-VDC/2
-VDC
© ABB Group
April 23, 2015 | Slide 40
Topology
Phase to ground voltage levels
VPH
+VDC
+VDC/2
NP
-VDC/2
-VDC
© ABB Group
April 23, 2015 | Slide 41
Topology
Phase to ground voltage levels
VPH
+VDC
+VDC/2
NP
-VDC/2
-VDC
© ABB Group
April 23, 2015 | Slide 42
Topology
Phase to phase voltage levels
© ABB Group
April 23, 2015 | Slide 43
Topology
Phase to phase voltage levels
© ABB Group
April 23, 2015 | Slide 44
Topology
Phase to phase voltage levels
© ABB Group
April 23, 2015 | Slide 45
Topology
Phase to phase voltage levels
© ABB Group
April 23, 2015 | Slide 46
Topology
Phase to phase voltage levels
© ABB Group
April 23, 2015 | Slide 47
Topology
Phase to phase voltage levels
© ABB Group
April 23, 2015 | Slide 48
Topology
Phase to phase voltage levels
3 level converter
3 level phase to GND
5 level phase to phase
Output sine filter required
5 level converter
(ACS 2000)
5 level phase to GND
9 level phase to phase
Output dV/dt filter
-> multilevel waveform
© ABB Group
April 23, 2015 | Slide 49
Semiconductor Technology
HV IGBT (High Voltage Insulated-Gate Bipolar Transistor)
§ Electrical Characteristics
§ Low Switching losses
§ Limited ability to absorb energy
§ Capable of tuning off short circuit
§ Separate Gate unit
§ HV chips
§ 6- 6.9kV configuration: 4.5 kV
§ 4.16kV configuration 3.3 kV
§ 3.3 kV configuration 3.3 kV
§ Mechanical Characteristics
§ Single Side Cooled
© ABB Group
April 23, 2015 | Slide 50
§ Simple Mechanically Integrate
Technology
Semiconductors
© ABB Group
April 23, 2015 | Slide 51
Semiconductor Technology
Protection against short circuit
§ IGBTs limit short circuit current
§ Device goes into Saturation
§ Resulting in Voltage across closed IGBT
§ IGBTs can turn off short circuit
§ Limited ability to absorb energy
§ Need to design fast detection and response to prevent
damage
§ Primary: Switch off IGBTs within 12 us
§ Module level response - Short Sensed at gate level
§ No need for Semiconductor Fuses in Power Part
§ Secondary: If short not cleared in 18us
§ System Level response
§ Crow Bar switched on, Protection Firing, then Line
Fuses decouple from Network within one cycle
© ABB Group
April 23, 2015 | Slide 52
Protection Concept
Protection against short circuit
Inverter
NP
semiconductor level or occurs in another part
of the drive (e.g. in the DC link) protection firing
is initiated.
+
§ Thyristor crowbar located in the DC link used
to discharge the main energy sources and to
prepare the drive for a safe protection firing.
Why are there still fuses in the converter?
§ 3 line fuses at the input of the drive used to
-DC
decouple the drive in case of a protection firing
§ No fuses in the power part (fuseless
protection)
© ABB Group
April 23, 2015 | Slide 53
Technology Rectifier Ridethrough performance
80 8000
Input current(A)
40 4000
20 2000
Typical torque
response (t) of a DTC
drive, compared with 0
0 1 2 3 4 5 6
0
9500
8000
Regeneration recovery
-50
Mode
0 1 2 3 4 5 6
time(s)
© ABB Group
April 23, 2015 | Slide 54
Control HW
Structure and Overview
© ABB Group.
April 23, 2015 | Slide 55
IOEC
Standard digital signal allocation
§ Voltage mode
§ Signal range 0 … 10 V
§ Load impedance 250 kΩ
§ Current mode
§ Signal range 0 … 20 ma
§ Load impedance 105kΩ
© ABB Group
April 23, 2015 | Slide 57
IOEC
Optional analog signal allocation
§ Voltage mode
§ Signal range 0 … 10 V
§ Load impedance 250 kΩ
§ Current mode
§ Signal range 0 … 20 ma
§ Load impedance 105kΩ
© ABB Group
April 23, 2015 | Slide 58
IOEC
Optional digital signal allocation
Navigation
keys
Supply OFF/
Discharging
Supply ON /
Charging
Scroll keys
Fault / Alarm
Local control
Ground switch keys
released
Emergency OFF
pushbutton
© ABB Group
April 23, 2015 | Slide 60
ACS 2000
Advanced software tools
© ABB Group
April 23, 2015 | Slide 61
Reliability
MTBF Calculation
By commodity By Sub-Assembly
PCBAs NP Frame
46% 12%
Passive
Components
11%
Availability: 99.9963%
© ABB Group
April 23, 2015 | Slide 62
ACS 2000
Simple and efficient maintenance
The ACS 2000 features
phase modules which
can be replaced within
Reliable components
minutes
§ Minimized parts count through multilevel
VSI topology results in increased
reliability
§ Extended Mean Time Between Failure
(MTBF) and improved availability
Easy access
§ Easy front access to all drive
components
© ABB Group
April 23, 2015 | Slide 63
Medium voltage drives
DriveMonitor TM intelligent monitoring
§ DriveMonitorTM is an intelligent
diagnostic system consisting of
§ Hardware module
(installed in- or outside of the drive)
§ Software layer
(collect and analyze selected drive
DriveMonitor signals and parameters)
§ Functions
§ Monitoring of drive’s performance,
and, if required, other shaft line
components (main circuit breaker,
transformer, motor)
§ Fast fault finding process
DriveMonitor 3000
© ABB Group
April 23, 2015 | Slide 64