Medium Voltage AC Drives for Speed and Torque Controlof 3 27 MW Motors

DriveIT ACS 6000

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ACS 6000 - The Worlds most Successful MV Multidrive

ABB's ACS 6000 medium voltage drive provides the optimum solution for

applications where high power and maximum reliability is required. Since

its introduction, the ACS 6000 has gained an excellent reputation for high

quality and reliability. As a result ABB has worldwide the largest installed

base of medium voltage multidrives incorporating the latest technology.

ABB's ACS 6000 is a modular drive designedfor the most demanding single-motor ormulti-motor applications. The optimumconfiguration for each application is reachedby combining the modules with minimumengineering effort resulting in lower investmentcosts and a smaller footprint. It is availablewith four sizes of inverter modules (3, 5, 7and 9 MVA).

Several motors can be linked to the ACS 6000via the common DC bus, enabling multi-machineoperation with only one multidrive converter.A multidrive, common DC bus converterprinciple offers a solution with optimumefficiency.

The ACS 6000 medium voltage drivecan be used in a wide range of industries.

Average annual increase of more than100 % since product launch

Largest installed base of medium voltagemultidrives worldwide

Operation experience of more than100 years

ACS 6000 Success

Mine hoists, conveyors, crushers and mills

Pumps, compressors, extruders, mixers and blowers

Main propulsion, thrusters, pumps and compressors

Rolling mills, coilers, pumps and fans

Fans, pumps, refiners and chippers

Fans and pumps

Pump applications, fresh water and waste water

Test stands and wind tunnels

Cement, Mining andMinerals

Other Applications

Water and Waste Water

Power Generation

Pulp and Paper

Metals

Marine

Chemical, Oil and Gas

Industries Applications

Fields of Application

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Key Features

The ACS 6000 medium voltage drive for speed and torque control of3 27 MW induction or synchronous motors is a member of the ABB AC drivesproduct family. It offers a number of unique key features.

DTC Control Platformfor exceptionally high torque andspeed performance

IGCT Power Semiconductorsfor highest reliability and efficiency

Line Supply Unitfor two-quadrant operation with aconstant power factor of 0.96 overthe whole speed range

Active Rectifier Unitfor four-quadrant operation and reducedharmonics, adjustable power factor

Common DC Busfor single and multiple-motor operationand energy recuperation

Modular Designfor optimum configurations

Powerful PerformanceFast and accurate process control incombination with low energy consumptionresults in top performance. The motor controlplatform of the ACS 6000 is based on ABBsaward-winning Direct Torque Control (DTC)technology. DTC provides the highest torqueand speed performance ever achieved inmedium voltage drives. As a result, controlof the drive is immediate and smooth underall conditions.

High Efficiency and ReliabilityThe ACS 6000 uses a revolutionary powersemiconductor switching device known asIGCT (Integrated Gate Commutated Thyristor)researched and designed by ABB. The use ofIGCTs results in a less complex, more efficientand reliable medium voltage drive, minimizingoperating and maintenance costs.

The ACS 6000 inverter topology

Key Product Features

ARU Active Rectifier UnitCBU Capacitor Bank UnitINU Inverter UnitLSU Line Supply Unit

12-Pulse LSU Single Drive

6-Pulse ARU Single Drive

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High AvailabilityMaximum reliability and short repair timeresults in a drive with high availability.

Optimized Energy FlowThe common DC bus allows several motors tobe connected to the same DC bus, providingan optimized energy flow.

The braking energy generated in one motorcan be transferred to other inverters via thecommon DC bus without power consumptionfrom the supply network. Due to the near unitypower factor throughout the whole speed rangethe energy efficiency is optimal.

Smooth System IntegrationThe ACS 6000 integrates easily into theindustrial environment because it can beoptimally configured for single-motor andmulti-motor applications without additionalcontrol equipment. The high power densityand compact design and the drivescommunication abilities minimize theoverall installation and operational costs.

The drive can be connected to the networkthrough one or several transformersdepending on power and harmonicsrequirements. Even a transformerlesssolution is available for certain applications.

High power and maximum reliability Smooth torque over the entire speed

range Applications operate at optimum

efficiency Compact and high power density Low noise and vibration levels Minimized energy consumption with

common DC bus Regeneration of rotating energy

ACS 6000 Advantages

Optimized energy flow with common DC buse.g. cold reversing steel mill

FlexibleOptimum ConfigurationThe modular design of the ACS 6000 allowsthe optimum configuration of any drive system.Each configuration, consisting of well-provenand certified modules, exactly fits thecustomers requirements.

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The ACS 6000 Medium Voltage AC DriveWater-cooled

User-friendly control panel forlocal operation Keypad with multi-language

display Main supply on/off pushbuttons Emergency stop pushbutton

DC bus groundingswitch for safety

EMC compliantcabinet for problem-free operation inelectromagneticenvironment

Electromechanicallyinterlocked doors ofpower sections forsafety

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Capacitor Bank Unit (CBU)DC capacitors forsmoothing theintermediate DC voltage

Water Cooling Unit (WCU)Supplies the coolingsystem with deionizedwater for the main powercomponents in LSU, INUand CBU

Terminal Unit (TEU)and Control Unit (COU)Contains the powerterminals and thecontrol swing frame

Inverter Unit (INU)Self-commutated,6-pulse, 3-level voltagesource inverter withIGCT technology

Line Supply Unit (LSU)6- or 12-pulse dioderectifier unit

Power Electronic Building Block (PEBB),one phase leg of a three-level VoltageSource Inverter (VSI) topology to beconfigured to act as an AC to DC orDC to AC converter

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Technology Highlights

Reliability has been the main guiding principle of the research anddevelopment activities for ABBs medium voltage AC drives.

Part CountThe fewer the parts the higher the reliability.ABB uses high power semiconductor switchingdevices and a topology that brings down thepart count to a minimum. This results in areliable, compact and service-friendly drive.

Fuseless DesignThe ACS 6000 medium voltage drive isdesigned to operate safely without fuses,resulting in less spare parts and better overallreliability. This allows fast startup after safetyinterruptions.

EncoderlessEncoders are known to cause failures due totheir exposed position on the motor. ABB'sACS 6000 medium voltage drive can operatewithout encoder, thereby reducing maintenancecosts and ensuring high levels of availability.

IGCT Switching DevicesABB has developed a high power semiconductorcalled IGCT (Integrated Gate CommutatedThyristor) to allow the use of modern controlalgorithms, which can eliminate harmonics,improve dynamic response time and maintain,or even control, the power factor.

Low LossesThe inherently low total losses of the IGCTrequire low cooling capacity and small coolingequipment.

ControlThe ACS drive control platform isbased on ABBs award-winningDirect Torque Control (DTC), resultingin the highest torque and speed performanceas well as lowest losses ever achieved inmedium voltage drives. Control of the drive isimmediate and smooth under all conditionsand the audible noise in the motor isconsiderably reduced.

What is Direct Torque Control?DTC is a revolutionary motor control methodfor AC drives that allows accurate control ofboth motor speed and torque without pulseencoder feedback from the motor shaft.In DTC, stator fluxand torque areused as primarycontrol variables.The motor statecalculations areupdated 40,000times a second(i.e. every 25 s)in the advancedmotor softwaremodel by thehigh-speeddigital signalprocessor. Due tothe continuous updating of the motor stateand the comparison of the actual values tothe reference values, every single switchingin the inverter is determined separately.DTC ensures the absolute lowest losses byswitching the power semiconductors onlywhen necessary.

Fast Response to Mains Fluctuations andProcess Side ChangesThe exceptionally fast torque step responseof the ACS 6000 means that it can respondto process and mains changes extremely fast.This enables easy handling of power-losssituations and sudden load changes.

ACS 6000

Typical torque (T) response of a DTC drive, comparedwith flux vector control with open loop pulse widthmodulation (PWM)

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Common DC BusThe ACS 6000 modularity is based on thecommon DC bus converter principle, whereseveral motors (synchronous and induction)can be connected to the same DC bus.With four sizes of inverter modules available(3, 5, 7 and 9 MVA), the optimum configurationfor a specific application can be reached bycombining the modules with minimumengineering effort. By linking the modules inparallel, the power can be increased to 27 MVA.

Multidrive topologies with a common DC busoffer a solution with optimum efficiency.Energy regenerated from one section inbraking mode can be directly used by anothersection via the DC bus without powerconsumption from the supply network.

ACS 6000 ModulesActive Rectifier Unit (ARU) , Inverter Unit (INU)The Active Rectifier Unit (ARU) rectifies the ACline voltage and charges the DC link capacitorswhereas the Inverter Unit (INU) inverts the DCvoltage to the AC motor voltage.

The layout and equipment of the INU and theARU are identical. They are self-commutated,6-pulse, 3-level voltage source inverters,incorporating IGCT technology for a reliable,fuseless operation with a smaller number ofdrive components.

The ARU allows four-quadrantoperation for regenerative braking,which reduces the overall energyconsumption.It controls the power factor to unityin the whole operating range evenat very low speeds.Optionally the ARU can bedimensioned to compensatereactive power generated by otherloads connected to the same network.

Line Supply Unit (LSU)The Line Supply Unit (LSU), designed fortwo-quadrant operation, maintains the powerfactor at 0.96 in the whole operating range.

Typically, the LSU is used for applicationswhich only require two-quadrant operation.If short-term braking capability is needed, aResistor Braking Unit with internal or externalresistors can be installed.

Diagram of common DC bus principle

Diagram showing theavailable active andreactive power of the ARU

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Modular Use, One Design

The ACS 6000 is designed as a set ofmodules. The modules are arrangedaccording to the required output power,motor configuration and process needs.

Single-Motor Drive Configurationsfor synchronous, induction andpermanent magnet motors. Single-motorconfigurations arecommonly used inapplications whichrequire large,independent anddecentralized drives.

Multi-Motor Drive Configurationsfor multiple synchronous or inductionmotors or a combinationof both types.Up to five motorscan be linked to acommon DC bus,enabling multiplemachine operation.Synchronous and/orinduction motors, highor low power, anycombination is possible in order toprovide the optimum configuration.

Redundant Drive Configurationsfor motors with two winding systems.Single drives can be configured to allowvarious schemes forredundancy offeringgreater availability ofthe drive system.

Twin Configurationsfor motors with winding systemssupplied on both endsby the converter. Thisallows higher converteroutput frequencies anddouble output voltage.

Converter rating optimally adapted tocustomer requirements.

Each configuration consists of well-proven modules, minimizing the risk ofdesign errors even when extensivesystems are engineered.

The compact, standardized design andthe integrated water-cooling systemreduce space requirements and havepositive impacts on room air conditioning.

Multidrive topologies with commonDC bus are possible.

Reduced installation and commissioningtime.

Benefits of Modularity

Depending on the application, the following four basic types of configurations are used:

The ACS 6000 is based on a modular product platform,expanding in line with customers requirements.

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ACS 6000 for Induction or Synchronous Motors

ACS 6000 for Induction MotorsSquirrel cage induction motors are theworkhorses of the industry due to theirversatility, reliability and simplicity. ABB'sbroad range of medium voltage AC inductionmotors includes ribbed cast iron fan cooledmotors and modular type welded framemotors.

The ACS 6000 is typically used with inductionmotors for applications such as pumps, fans,compressors, conveyors, hoists, mills, crushersand propulsion systems.

ACS 6000 for Synchronous MotorsSynchronous motors are typically consideredfor higher power ratings (e.g. above 8 MW tomore than 100 MW). In addition to their highpower capabilities, synchronous motors offera wide field weakening range as well as thebenefits of high efficiency and highperformance.

The ACS 6000 synchronous drive is ideal forapplications which require dynamic responseand high torque, such as rolling mills andmine hoists and for high power applications,such as marine propulsion drives.

For special applications (e.g. low speedpumps) the ACS 6000 can used withpermanent magnet motors.

Depending on the power rating and the application characteristics,the ACS 6000 can be used with induction or synchronous motors.

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Control SystemABB offers an open communication strategyenabling connection to a PLC (ProgrammableLogic Controller) or a DCS (Distributed ControlSystem). Fieldbus connectivity with a widevariety of protocols is available.

The ACS 6000 product family platform offersthe possibility to monitor the transformers aswell as the motors with the drives controlsystem.

System Integration

The ACS 6000 can either be installed tocontrol just one motor, or to control severalmotors with comprehensive control features,minimizing overall installation and operationalcosts. The drive can be supplied by one orseveral transformers depending on powerand harmonics requirements. Even atransformerless solution is available forcertain applications.

The ACS 6000 medium voltage drive with its modular conceptallows optimum integration into the customers industrialenvironment.

Low network harmonics High power factor Optional reactive power (VAr)

compensation Small footprint Fast commissioning EMC compliant

ACS 6000 System Integration

Applicable StandardsThe ACS 6000 meets the IEEE 519-1992 andIEC 61000-2-4 specifications for voltage andcurrent harmonic distortion for virtually allinstallations. This eliminates the need forexpensive harmonic filters and protects otherelectrical equipment from harmonic disturb-ances.

The ACS 6000 meets EN (IEC), CE, UL*, cUL*

and other standards to ensure smooth systemintegration worldwide.* on request

Smooth Integration into Existing Systems

CommissioningThe ACS 6000 is easy to commission.In its multidrive configuration, the ACS 6000is much faster to commission than theequivalent number of single drives.

Scope of ACS 6000 system integration

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The Principle of Industrial IT

ABBs IndustrialIT means increasedstandardization and seamless interactionof different ABB products.The ACS 6000 has been certified to bearthe IndustrialIT Enabled symbol, a specialmark indicating that the drive can be easilyintegrated into the IndustrialIT architecturein a plug & produce manner.

Easy integration of the drive intocustomers industrial environment

All drive information readily availablein electronic form

Drive communication with theenvironment through control panels,standardized fieldbus adapters andinterfaces (OPC, OLE for ProcessControl)

Easy to use start-up and maintenancetools

Benefits

ProcessControllers

Customer support systemsfor product training, helpdesk, service

Business systems forsourcing, ordering,spare parts

Software for dimensioning,configuration, start-up,monitoring, documents

Software tools for energycalculations, efficiencyanalysis, new drive selection

Variable SpeedDrives

Electricalmachinery inthe process

ApplicationController

Fieldbus

ControlNetwork

IndustrialIT and DriveIT

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The ACS 6000 incorporates the same suite of user-friendly toolsas other drives of the ACS product family.

DriveWindowDriveWindow is an advanced, easy-to-usetool for commissioning, maintenance, remotediagnostics and monitoring of drive systems.

Features

Access to all drives connected to the samenetwork

Graphical presentation of signal values Monitoring and editing of drive signals

and parameters off-line or on-line Back-up of drive parameters

File can be easily reloaded Fault diagnosis with indication of drive

status and fault history Modbus compatibility, RS485

PrintScreen of DriveWindow

DriveOPCDriveOPC is a software package, whichallows communication between Windowsapplications and ABB drives.

Features

Controlling and monitoring with PC-basedprocess control software

Standard interface Remote connection via LAN (Local Area

Network) Access to

drive control signals and parameters data and fault loggers

DriveWare, the Tools to Increase Availability

Principle of DriveOPC

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Service and Support

Dedicated Test FacilityRoutine tests of the ACS 6000 include testssuch as visual and mechanical checks, waterpressure tests, insulation tests, auxiliary,control and protection devices checks andrated current and temperature rise tests of theInverter Unit.

ACS 6000 Single DriveTests of the ACS 6000 single drive additionallyinclude load and functional tests on the testlab motor.

ACS 6000 MultidriveThe multidrive modules are tested separatelyone by one as well as in a line-up, where thecontrol functionality of the entire drivesystem is tested.

Extended TestingIf required ABB also offers the possibilityto perform extended testing in ABBs testfacilities (see illustration).

TrainingExtensive training for ABBs medium voltagedrives can be provided at the ABB Universityin Turgi, Switzerland. A range of training isoffered from basic tutorials to programstailored to the customers specific needs.

-> www.abb.com/abbuniversity

Services for ABBs Medium Voltage Drives Installation and commissioning Training On-board diagnostics Remote diagnostics Customized service programs Local technical support Local service support Spare parts and logistics network Worldwide service network 24 x 365 support line

Extensive ExperienceAs originators of AC drives technology in the late1960s, ABB has over 30 years of applicationknow-how in all industrial sectors, in virtuallyevery country. ABB has listened to customersand strives to develop products which fulfilltheir needs.

Support and ServiceABBs experts will assist in sizing, designingand commissioning the new drive.

After sales service is an integral part ofproviding the customer with a reliable andefficient drive system. ABB has the largestservice organization worldwide, which backsevery drive ABB delivers.

Illustration of extended test layouts

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ABB Switzerland LtdMedium Voltage DrivesCH-5300 Turgi / Switzerland

Tel +41 (0)58 589 27 95Fax +41 (0)58 589 29 84Email mvdrives@ch.abb.comI-Net www.abb.com/motors&drives 3B

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