ABB ACS 6000 Tech Catalog RevD

ACS 6000

Technical Catalog

Water-cooled ACS 6000

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Table of Contents

List of Figures 9

List of Tables 13

Chapter 1 - Overview 15

1.1 Introduction 151.2 Modular design 161.3 Technological highlights 171.4 Standard applications 181.5 Benefits for the customer 191.6 CE marking 21

Chapter 2 - Types and applications 23

2.1 General 232.2 The ACS 6000 drive types 232.2.1 Single-motor drives 232.2.2 Multi-motor drive 252.2.3 Redundant configurations 272.3 Application examples 272.3.1 Marine propulsion and thruster drives 272.3.2 Rolling mill applications 302.3.3 Mining applications 35

Chapter 3 - Functional description, operation 37

3.1 General 373.2 Standard control functions 373.2.1 Direct torque control 373.2.2 Motor control functions 413.2.3 Active rectifier control functions 423.2.4 Application control functions 423.3 Operation and diagnostics 443.3.1 Local and remote operation 443.3.2 Standard diagnostic functions 493.4 Standard protection functions 493.4.1 General 49

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3.4.2 Protection functions related to drive system 503.4.3 Internal converter protection functions 523.4.4 External protection functions 523.4.5 Manually initiated protection functions 533.5 Other features 533.6 Optional features 54

Chapter 4 - Hardware design, technology and configuration 55

4.1 Overview 554.2 Technology 554.2.1 Common DC bus 554.2.2 Fuseless design 604.2.3 IGCT power semiconductor 604.3 Cabinet layout 614.4 Cabinet design 624.4.1 Mechanical design 624.4.2 Electromagnetic compatibility (EMC) 634.4.3 Safety aspects 634.5 Busbars and grounding 644.6 Auxiliary supply system 654.6.1 3-phase supply 654.6.2 3-phase supply and separate UPS for control power 664.7 Cooling system 67

Chapter 5 - Hardware design, description of converter units 69

5.1 Overview 695.2 Available modules 695.3 Line supply unit (LSU) 705.3.1 Overview 705.3.2 12-pulse LSU 705.3.3 6-pulse LSU 735.4 Active rectifier unit (ARU) 745.4.1 Overview 745.4.2 Main components 765.4.3 Circuit diagram 775.5 Inverter unit (INU) 785.5.1 Overview 785.5.2 Circuit diagram 795.6 Capacitor bank unit (CBU) 805.6.1 Overview 805.6.2 Main components 80

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5.6.3 Circuit diagram 825.7 Terminal unit (TEU) 825.7.1 Overview 825.8 Control unit (COU) 835.8.1 Overview 835.8.2 Main components 865.9 Water cooling unit (WCU) 875.9.1 Overview 875.9.2 Water cooling system 875.9.3 WCU types and sizes 885.9.4 Main components 915.9.5 Cooling control 925.9.6 Raw water connection 935.9.7 Technical data 935.9.8 Options for WCU 935.9.9 Air-to-air heat exchangers 935.10 Customer interface unit (CIU) 945.10.1 Overview 945.10.2 Main components 955.11 Input filter unit (IFU) 965.11.1 Overview 965.11.2 Main components 965.11.3 Circuit diagram 975.12 Voltage limiter unit (VLU) 975.12.1 Overview 975.12.2 Main components 985.12.3 Circuit diagram 995.13 Resistor braking unit (RBU) 995.13.1 Overview 995.13.2 Main components 1005.13.3 Circuit diagram 1015.14 Braking chopper unit (BCU) 1015.14.1 Overview 1015.14.2 Main components 1015.14.3 Circuit diagram 1025.15 Excitation Unit (EXU) 102

Chapter 6 - Control system and process interfaces 103

6.1 Overview 1036.2 Hardware and structure of the control system 1036.2.1 Hardware 1036.2.2 Configuration examples 1056.3 Local control devices 1096.3.1 CDP local control panel 109


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6.3.2 CDP control panels, control switches and indicator lamps 110

6.4 Fieldbus interfaces 1146.4.1 Fieldbus types 1146.4.2 Signals 1156.5 Hardwired process I/Os 1186.5.1 Standard S800 I/O modules 1186.5.2 Customer control signals 1196.5.3 Interface configurations 1196.6 Control software 1226.6.1 Control software structure 1226.6.2 Operating system 1236.6.3 Motor and rectifier control software 1236.6.4 Fixed application software 1236.6.5 FCB application software 1246.6.6 Panel application software 1246.7 Control options 124

Chapter 7 - Engineering information 125

7.1 General 1257.2 Main circuit breaker 1257.3 Main transformer 1267.3.1 Main transformer for ARU 1267.3.2 Main transformer for LSU 1267.4 ARU synchronization transformer 1267.5 Asynchronous motor requirements 1267.6 Synchronous motor requirements 1267.7 Excitation supply 1277.8 Selection of power cables 1277.8.1 Power cable dimensioning 1277.9 Control cabling 128

Chapter 8 - Installation guidelines 129

8.1 General 1298.2 Ambient conditions 1298.3 Transport 1298.4 Installation site requirements 1318.5 Raw water flanges 1328.6 Power cable installation, grounding and shielding 1338.6.1 Sealing system for power cable entry 1338.6.2 Connecting ARU to supply transformer 1348.6.3 Connecting LSU to supply transformer 1368.6.4 Connecting motor to INU 137


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8.7 Equipment grounding 1378.8 Installation of auxiliary power and control cables 138

Chapter 9 - Ordering information 141

9.1 General 1419.2 Drive selection 1419.2.1 Required application data 1419.2.2 Configuration procedure 1419.2.3 Configuration rules 1429.3 Type code 1429.4 Option list 1429.5 External system data 1429.6 Technical data 143

Chapter 10 - Options 145

10.1 Converter hardware 14510.2 Options for WCU 14610.3 Converter software 14710.4 Service and diagnostics 14710.5 Optional customer interfaces 15010.5.1 I/O with option CIW1 (standard software) 15010.5.2 I/O with option CIW2 and CIW3

(project specific SW) 15010.5.3 I/O with option CIUe 15010.5.4 AC 80 / AC 800 controller 15010.6 Marine version 15110.7 Transportation, installation and commissioning 15310.8 Training 15310.9 Testing 15310.10 Documentation 154

Index 155


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List of FiguresFigure 1-1 ACS 6000, typical marine configuration

with air-to-air heat exchanger 15Figure 1-2 ACS 6000, typical standard configuration

with active rectifier without air-to-air heat exchanger 16

Figure 1-3 Typical examples for basic configurations 17Figure 2-1 Single-motor drives, basic configurations 24Figure 2-2 Single-motor drive, SD type, example with

active rectifier 25Figure 2-3 Example of a standard multi-drive

configuration 26Figure 2-4 Example of system configuration for

offshore drilling rig 28Figure 2-5 Redundant main propulsion system 29Figure 2-6 Configuration for a service vessel 30Figure 2-7 Hot rolling mill train: overview 31Figure 2-8 Rougher mill train 32Figure 2-9 Reversing steckel mill 33Figure 2-10 Sendzimir mill 34Figure 2-11 Mine hoist 35Figure 2-12 Overland conveyor 36Figure 3-1 DTC block diagrams 38Figure 3-2 DTC: typical dynamic speed response 40Figure 3-3 DTC vs. PWM: Typical torque response times 40Figure 3-4 Typical ramp shapes 41Figure 3-5 Setting the control panel to local / remote 44Figure 3-6 Start sequence with ARU 45Figure 3-7 Start sequence with LSU 46Figure 3-8 Stop and off sequence with ARU 47Figure 3-9 Stop and off sequence with LSU 48Figure 3-10 Emergency off sequence 48Figure 3-11 Stall region of the motor 51Figure 4-1 Common DC bus principle 56Figure 4-2 Converter principle diagram 57Figure 4-3 Phase voltage created by ARU 57Figure 4-4 Vector control principle 58Figure 4-5 Active rectifier control block diagram 59Figure 4-6 IGCT 60Figure 4-7 ACS 6000 basic configuration with LSU 61Figure 4-8 ACS 6000 basic configuration with active

rectifier and input filter unit 62Figure 4-9 Arrangement of busbars 64Figure 4-10 "AC safe line" auxiliary concept 66Figure 4-11 3-phase auxiliary supply and AC UPS 66


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Figure 4-12 3-phase auxiliary supply and DC UPS 67Figure 4-13 Principle diagram of the water cooling circuit 67Figure 5-1 Cabinet layout of 12-pulse LSU 71Figure 5-2 Circuit diagram of 12-pulse LSU 72Figure 5-3 Cabinet layout of 6-pulse LSU with IRU 73Figure 5-4 Circuit diagram of 6-pulse LSU with IRU 74Figure 5-5 ARU cabinet layout 75Figure 5-6 Phase module with IGCTs 76Figure 5-7 ARU local control and monitoring equipment 77Figure 5-8 ARU circuit diagram 77Figure 5-9 3 and 5 MVA Units 78Figure 5-10 7, 9 and 11 MVA INUs 79Figure 5-11 Circuit diagram of 7, 9 and 11 MVA INUs 79Figure 5-12 Circuit diagram of 3 and 5 MVA units 80Figure 5-13 CBU cabinet layout 81Figure 5-14 CBU circuit diagram 82Figure 5-15 TEU (1000 mm wide) 83Figure 5-16 COU control swing frame installed in a TEU

(typical configuration) 84Figure 5-17 Reverse side of COU doors

(typical configuration) 85Figure 5-18 Principle illustration of water cooling circuit 87Figure 5-19 WCU - closed to atmospheric pressure 88Figure 5-20 Principle flow diagram of a WCU with a

closed circuit 89Figure 5-21 WCU open to atmospheric pressure 90Figure 5-22 Flow diagram of WCU with open circuit 91Figure 5-23 Roof heat exchangers 94Figure 5-24 CIU, typical cabinet layout 95Figure 5-25 IFU cabinet layout 96Figure 5-26 IFU circuit diagram 97Figure 5-27 VLU cabinet layout 98Figure 5-28 VLU circuit diagram 99Figure 5-29 RBU cabinet layout 100Figure 5-30 RBU circuit diagram 101Figure 5-31 BCU circuit diagram 102Figure 6-1 Single-motor drive with ARU 105Figure 6-2 Single-motor drive with ARU

(example with water-cooled EXU) 106Figure 6-3 Single-motor drive with LSU 107Figure 6-4 Multi-motor drive with ARU 108Figure 6-5 Multi-motor drive with double ARU 108Figure 6-6 Single-motor drive with double ARU

and double INU 108Figure 6-7 CDP control panel 110Figure 6-8 ARU control panel 111Figure 6-9 INU control panel 112


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Figure 6-10 Control panel on additional control units 113Figure 6-11 Grounding switch on CBU 114Figure 6-12 S800 I/O station 118Figure 6-13 S800 I/O configuration of an ACS 6000

single drive 119Figure 6-14 ACS 6000 single-motor drive with

option CIW1 120Figure 6-15 Typical ACS 6000 multi-motor drive

with option CIU2 121Figure 6-16 Software block diagram of the AMC controller 122Figure 7-1 Excitation transformer schemes for

multi-motor drives 127Figure 8-1 Cabinets with base frame and without door

handles 130Figure 8-2 Cabinets with base frame and marine-type

door handles 130Figure 8-3 Cabinets without base frame 130Figure 8-4 Space requirements (dimensions in mm) 131Figure 8-5 Flanges 133Figure 8-6 Power cable entry with roxtec sealing system 134Figure 8-7 ARU side cabling 135Figure 8-8 LSU side cabling 136Figure 8-9 INU side cabling 137Figure 8-10 TEU, connection to system ground 138Figure 8-11 Control cable entry with roxtec sealing system 138Figure 10-1 Output switch types 145Figure 10-2 Leakage sensor 146Figure 10-3 Typical DriveWindow display 148Figure 10-4 ACS 6000 with DriveMonitorTM installed

in a console 149Figure 10-5 S800 I/O configuration with AC 80 / AC 800 151Figure 10-6 Marine version 151Figure 10-7 Door arrester 152Figure 10-8 Roof fixings 152Figure 10-9 Roof connecting pieces 153


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List of TablesTable 2-1 Case study: power requirements of a

sendzimir mill with ACS 6000 34Table 3-1 DTC versus current vector control 39Table 4-1 IGCT technology compared to GTO

and IGBT 61Table 6-1 Fieldbus adapters 114Table 6-2 Basic data exchange between AMC and

process control: analog and binary inputs 116Table 6-3 Basic data exchange between AMC and

process control: analog and binary outputs 117Table 6-4 S800 I/O modules 118Table 7-1 Control cable requirements 128


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Chapter 1 - Overview

1.1 IntroductionThe Technical Catalog describes the main electrical, mechanical and environmental features of the ACS 6000, the modular medium voltage drive for megawatt class applications in the 3 kV range. In addition, the Catalog illustrates the various options available for the drive and offers advice on selecting a motor and drive combination. It also provides useful installation tips.

For general information on the ACS 6000 refer also to the ACS 6000 Brochure.

The ACS 6000 is a medium voltage, variable speed frequency converter for high power induction and synchronous motors. The ACS 6000 covers a power range from 3 to 27 MVA and delivers output frequencies from 0 to 75 Hz.

Figure 1-1 ACS 6000, typical marine configuration with air-to-air heat exchanger


Chapter 1 - Overview ABB

Figure 1-2 ACS 6000, typical standard configuration with active rectifier without air-to-air heat exchanger

1.2 Modular designThe ACS 6000 features a modular design based on standardized cabinet units. Each unit is dedicated to a specific function. The units are combined according to the required output power, motor configuration and process needs.


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Figure 1-3 Typical examples for basic configurations

Refer to Chapter 5 - Hardware design, description of converter units for identification of the units.

Depending on the application, four different types of configurations are available (Figure 1-3):

• Single-motor drive configurations for synchronous or asynchronous motors

• Multi-motor drive configurations for multiple synchronous or asynchronous motors or combinations of both types

• Redundant drive configurations for motors with two winding systems

• Twin configurations for motors with winding systems supplied on both ends by the converter

1.3 Technological highlightsThe following features distinguish the ACS 6000 from other converters on the market:

Direct torque control Direct Torque Control (DTC) enables highest torque and speed control performance ever achieved in medium voltage drives. DTC allows:

• Torque response times up to 10 times faster than conventional control methods using flux vector or pulse width modulation

• Minimal torque ripple

Single drive with diode rectifier

Multi-drive with active rectifier

Redundant drive with diode rectifier (planned solution)



• Acccurate static speed and torque control.

Integrated gatecommutated thyristor

The Integrated Gate Commutated Thyristor (IGCT) is a power semicon-ductor switching device specifically developed for medium voltage converters. Based on well established GTO (Gate Turn Off Thyristor) technology, it enables intrinsically less complex, more efficient and reliable converter designs.

IGCTs combine high speed switching capabilities as known from IGBTs (Insulated Gate Bipolar Transistors) with high blocking voltage and low conduction losses as known from GTOs.

Active rectifier unit The Active Rectifier Unit (ARU) allows four-quadrant operation. Thus regenerative braking is possible in both rotating directions of the motor over the whole power range.

The ARU controls the power factor to unity in the whole operating range even at very low speeds. Optionally the ARU compensates reactive power generated by other loads connected to the same network.

The ARU reduces and eliminates harmonics in the voltage applied to the mains by using pre-defined, optimized pulse patterns.

LSU The Line Supply Unit designed for two-quadrant operation maintains the power factor at 0.95 in the whole operating range.

Common DC bus Multiple rectifiers and motor inverters can be connected to the same DC bus. This allows several drives to be combined into one converter unit.

Braking energy generated in one motor can be transferred to other inverters via the common DC bus without loading the rectifier.

1.4 Standard applicationsThe ACS 6000 provides the optimum solution for marine and industrial medium voltage drive applications. Typical fields of applications are:

Marine • Main propulsion systems

• Thruster drives

Oil and gas • Compressors

• Pumps

Metals and mining • Rolling mills

• Mine hoists

• Overland conveyors

• Crushers and mineral mills

General industry • Variable speed fans and pumps

• Pump storage plant drives


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• Teststand.

1.5 Benefits for the customerMaximum availability High reliability and short repair time result in maximum availability.

High reliability is achieved by:

• Proven technology:

The design of the IGCT used in the ACS 6000 is based on well proven GTO technology. IGCTs have been used successfully in medium voltage converters for more than 5 years.

• Low parts count:

The fast switching capability of the IGCT allows snubberless circuit topologies. This results in a smaller number of power components which improves the operational reliability.

• Fuseless design:

Avoiding the use of unreliable fuses results in better overall reliability.

Short repair time is achieved by:

• Diagnostics system:

A comprehensive self diagnostic monitoring system generates concise error messages with information on error type and location. This enables quick and precise localization of disturbances and reduces time spent on fault finding.

• Simplicity of power circuit:

The simplicity of the power circuit and the modular design of the hardware do not only lead to extremely high availability but also provide the base for a maintenance and repair concept which is characterized by minimum outage times, e.g. a complete phase module can be exchanged in less than 1 hour.

Top performance Fast and accurate process control in combination with low energy consumption provides top performance.

Fast and accurate process control based on DTC results in high and constant production quality and minimum machinery wear. DTC guarantees:

• Highly dynamic response times without overshoot

• Accurate static speed and torque control

• Smooth output current waveforms resulting in minimum torque ripple.

Low energy costs are achieved by:

• Minimal reactive power consumption



The reactive power demand of the drive can be neglected by using ARU or LSU (see Chapter 4 - Hardware design, technology and configuration, Power factor control). The supply system needs only to be designed for effective power consumption. Additional reactive power compensators are not needed.

• Multi-drive topology

The common DC bus enables further energy savings with multi-motor arrangements. Energy regenerated from one section in braking mode can be used by other sections directly via the DC link. This is achieved without loading supply transformers or the network.

• Four-quadrant operation

Drives equipped with ARU are suitable for regenerative braking. This reduces the overall energy consumption in many applications.

Low maintenance cost Maintenance costs are minimized due to extended maintenance periods, low number of maintenance tasks and maintenance on the running system.

Extended maintenance periods and fewer maintenance tasks are achieved due to water cooling:

• Easy wearing parts, such as fans and bearings needed in air-cooled systems, are not used.

Maintenance on running system:

• The maintenance or replacement of redundant cooling pumps can be done on the running system.

• Air-to-air heat exchanger.

What you need is whatyou get

Customer requirements are precisely met. The flexible design with standard converter units and the well proven control platform allow the optimum configuration of the drive system.

Modular design:

• Converter rating fits exactly customer requirements.

• Each configuration consists of well proven and certified converter units, thus minimizing the risk of design errors.

• The compact, standardized design and the integrated water cooling system reduce space requirements and have positive impacts on room conditioning.

• Multi-drive topologies with common DC bus are possible.

In applications where parallel driving and braking is needed, the ratings of converter transformers, breakers and cables can be reduced.

• Installation and commissioning time is reduced compared to engineered systems due to standardized procedures and documen-tation.


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Well proven ABB AC drives control platform:

• Configurable application software and standard interfaces for hardwired I/Os allow optimum integration into the industrial environment.

• Interfaces for all common fieldbus types are available for communi-cation with the overriding control system.

• Standardized control panels and operational tasks, common for all ABB AC drives, allow a simple and user-friendly operation.

1.6 CE markingThe ACS 6000 frequency converter is marked with a CE symbol.The CE marking indicates that the ACS 6000 complies with the basic technical requirements and conformity valuation criteria and is an essential requirement of the relevant EC directives.




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Chapter 2 - Types and applications

2.1 GeneralThis chapter provides information about the modular structure of the ACS 6000. A number of typical examples from the marine and industrial field illustrate how the modular concept of the ACS 6000 is applied to provide the optimum converter configuration for high-power applications.

The design of the ACS 6000 is characterized by the common DC bus. Depending on the individual drive configuration and the power demands of the process, multiple LSUs or ARUs are connected together with motor inverters to the same DC bus.

2.2 The ACS 6000 drive types

2.2.1 Single-motor drivesSingle-motor configurations are commonly used in applications which require large and independent drives, such as:

• Main propulsion drives for shuttle tankers, cruisers and ferries

• Thruster drives for dynamic positioning of drilling vessels or floating production vessels

• Mining and general industrial applications with large fans, pumps, compressors, crushers or hoists

• Individual rolling mill stands.

Basic configuration The basic configurations for single-motor applications of up to 11 MVA are shown in Figure 2-1.

• The rectifier is connected to the input transformer (LSU, a and c in Figure 2-1, or ARU, b and d in Figure 2-1).

• The INU feeds the motor.

• For smoothing the DC voltage, a CBU is connected to the DC bus.

• In case of a synchronous motor, an EXU is added to the configuration (see bottom of Figure 2-1).

The TEU and COU and the WCU complete the basic converter. BCU, RBU and/or VLU are optional.


Chapter 2 - Types and applications ABB

Figure 2-1 Single-motor drives, basic configurations

The figure above shows the basic configurations of the ACS 6000 for induction motors (A,B) and synchronous motors (C,D).

Single drives withmultiple units

For powerful single drives, rectifier and inverter units are used in parallel: LSUs or ARUs on the supply side and two INUs on the motor side.

Mains

Mains

Mains

Mains

Aux. power

Aux. power

Aux. power

Aux. power

Excitation power Excitation power

A B

C D

Synchronization voltage



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Figure 2-2 shows a typical example of a parallel configuration with multiple units:

• Two INUs and a 12-pulse supply with two ARUs for a synchronous motor

Depending on the application, other configurations with LSU and/or induction motor are possible. The dimensions of CBU and WCU depend on the rated converter power.

Figure 2-2 Single-motor drive, SD type, example with active rectifier

2.2.2 Multi-motor driveMulti-motor configurations consist of individual motors which form a functional unit as in the following applications:

• Sendzimir mills, rolling mill trains and continuous strip production lines

• Conveyors

• Marine propulsion and thruster drives

• Drilling packages

• Pulp & Paper

• Test stands, e.g. for gearbox test systems

Mains

Aux. power

Excitation power




Multi-motor drives have the advantage that the number of MCBs and converter transformers is reduced.

Motors with the same or different power rating are fed from the common DC bus of the converter (see Figure 2-3, Figure 2-6 and following).

Synchronous and induction motors can be part of the same line-up. Depending on the type of rectifier, a maximum of 4 or 5 INUs can be connected.

Multi-motor drives require a separate COU for each motor and an EXU for each synchronous motor.

In applications with parallel driving and braking, the ratings of rectifier unit, main circuit breaker and transformer can be reduced substantially when only the net-power demand has to be drawn from the supply busbar (see Table 2-1).

Figure 2-3 Example of a standard multi-drive configuration

Mains

Synch. reference

Aux. power

Excitation power


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2.2.3 Redundant configurationsThe ACS 6000 allows various schemes for redundant drive configurations. Thus operation at reduced power is maintained in case of a partial failure of the converter.

An example is given in Propulsion and thruster for shuttle and service vessels, page 28. The configuration shows a standard drive for a redundant main propulsion system with a tandem motor for marine appli-cations. The DC bus can be split with an ISU and the converter units are arranged symmetrically with two separate feeders.

2.3 Application examples

2.3.1 Marine propulsion and thruster drivesElectric propulsion is widely used in today‘s marine technology. The modular ACS 6000 is the perfect answer to the requirements of modern propulsion schemes for floating production facilities, dynamically positioned drilling vessels, shuttle tankers, service ships and large passenger vessels. Reasons for choosing the ACS 6000 are:

• Outstanding reliability

• Small footprint and weight of propulsion system

• High immunity to varying climatic conditions and vibrations

• High and smooth torque over entire speed range.

Dynamic positioning offloating vessels

Figure 2-4 shows a typical example for a dynamically positioned offshore drilling rig. It is equipped with four ACS 6000 single drives.



Figure 2-4 Example of system configuration for offshore drilling rig

Propulsion and thrusterfor shuttle and service

vessels

Figure 2-5 shows an example of a redundant main propulsion system where the power system can be split. The main propeller (Azipod or conventional installation with shaft) is driven by a variable speed tandem motor fed by a redundant ACS 6000 converter. For positioning and manoeuvring, 2 x 2 thrusters on a common DC bus (Azipod and propeller units) are provided.

Mains

Mains

Mains

Mains

Aux. power

Aux. power

Aux. power

Aux. power


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Figure 2-5 Redundant main propulsion system

Main propulsion withazipod thrusters

Figure 2-6 shows a typical configuration for a service vessel with two main propulsion Azipod thrusters assisted by two smaller (tunnel) thrusters. This type of configuration is used in case of smaller power requirements. An arrangement with two ACS 6000 multi-drives and line reactances instead of transformers is the most feasible solution.

Aux. power

Aux. powerAux. power

Aux. power

MainsMains

MainsMains

Excitation power



Figure 2-6 Configuration for a service vessel

2.3.2 Rolling mill applicationsMetals applications are characterized by quickly changing loads, fast changes between driving and braking operations, constant torque in a wide speed range and high torque steps.

The main reasons for choosing the ACS 6000 in rolling mill applications are:

• Fast and precise torque and speed control under varying loads

• Full four-quadrant operation with active rectifier

• Reduced energy consumption with common DC bus.

Hot rolling mill train The ACS 6000 with its modular concept is the perfect answer to the requirements of the metals industry. This is illustrated in the following examples.

Mains MainsAux. power Aux. power


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Figure 2-7 Hot rolling mill train: overview

Rougher mill train A typical rougher mill consisting of edger, rougher and crop shear is shown in Figure 2-8. Edger and crop shear are equipped with relatively small drives (crop shear with up to 300% overload capability). These drives can be combined into one single ACS 6000 multi-drive scheme. Synchronous and induction motors can be combined.

Two separate ACS 6000 single drives are used for the rougher mill stand. Each of the two synchronous motors is equipped with two three-phase winding systems.

Edger mill Rougher mill Crop shear

Reversing steckel mill

Hot tandem mill



Figure 2-8 Rougher mill train

Reversing steckel mill A typical converter arrangement for a reversing steckel mill is shown in Figure 2-9.

The drives for entry and exit coilers and the drive for the down coiler are combined into one ACS 6000 multi-drive. The energy generated on the decoiling side is transferred via the common DC bus to the other coiler without loading the supply line. Therefore the net-power demand is reduced.

Mains

Synch. referenceAux. power

Excitation power

Mains Mains

Aux. power

Excitation power

Aux. power

Excitation power

Synchronization voltage Synchronization voltage


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The two main mill drives with synchronous motors are equipped with ACS 6000 single drives. To provide sufficient overload capabilities each motor is fed by two INUs.

Figure 2-9 Reversing steckel mill

Sendzimir mill The sendzimir cold rolling mill consists of a mill stand and two tension reels as shown in Figure 2-10. The whole system can be realized with one ACS 6000 multi-drive.

The energy generated by the braking reel is transferred via the common DC bus to the driving reel without loading the supply line. Therefore the net-power demand is reduced. The supply rating can be reduced by almost 50% compared to a setup with individual drives see Table 2-1.

Mains

Synch.referenceAux. power

Mains Mains

Excitation power

Aux. power

Excitation powerAux. power

Synchronization voltage Synchronization voltage



Figure 2-10 Sendzimir mill

Table 2-1 Case study: power requirements of a sendzimir mill with ACS 6000

Synch.reference

Aux. power

Excitation power

Mains

Estimated power requirement Converter rating

Main drive 4 MW with 200% overload capability 9 MVA

Tension reel 1 4 MW with 200% overload capability 9 MVA

Tension reel 2 4 MW with 200% overload capability 9 MVA

Total supply with individual drives

3 x 4 MVA with 200% overload capablity 3 x 9 MVA = 27 MVA

Total supply with common DC bus

1.2a x 4 MVA with 200% overload capability

a. Dimensioning factor

2 x 7 MVA = 14 MVA


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2.3.3 Mining applicationsThe mining sector includes a wide field of drive applications. Depending on the process needs the requirements vary.

The main reasons for choosing the ACS 6000 in mining applications are:

• High reliability

• High torque over entire speed range especially when starting from zero speed

• Full four-quadrant operation with active rectifier

• Small footprint

• Power factor of 1 (negligible voltage drop)

• Input filter unit (IFU).

The optional unit is used when the drive is supplied by a weak network. The IFU also reduces the harmonic voltages injected to the network.

Mine hoists Figure 2-11 shows an example of a mine hoist with double INU for very low speed and high overload capability.

Figure 2-11 Mine hoist

Mains

Excitation power

Aux. power




Overland conveyor Long overland conveyors may have an overall length of several kilometers. In terrains with long declining sections high braking capabil-ities are needed and the drive is mainly operating in regenerative mode. Regenerative braking requirements can be met optimally by using the ACS 6000 with active rectifier.

Figure 2-12 shows an example with four parallel induction motors driving an overland conveyor belt.

Figure 2-12 Overland conveyor

Mains

Synch. referenceAux. power


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Chapter 3 - Functional description, operation

3.1 GeneralThis chapter provides information about the standard control, monitoring and protection functions of the ACS 6000. A description of the basic operation and diagnostic devices is included as well. The description of the related control hardware, software and customer interfaces can be found in Chapter 6 - Control system and process interfaces.

Links to otherdocuments

Summary of references to linked documents in this chapter:

• Appendix - Technical data

3.2 Standard control functionsThe ACS 6000 control system is based on ABB's well-proven ACS frequency converter control platform which includes the very successful high-end, low voltage frequency converters family ACS 600, ACS 800 as well as the medium voltage frequency converters ACS 1000, ACS 2000, ACS 5000 and ACS 6000. The control system is fully based on micropro-cessor technology and offers a wide range of unique control features.

The most relevant control, monitoring and protection functions which are set with parameters are discussed in this chapter. These functions are integrated in the control system described in Chapter 6 - Control system and process interfaces.

3.2.1 Direct torque controlDirect Torque Control (DTC) enables highest torque and speed control performance ever achieved with medium voltage drives.

3.2.1.1 DTC principle

DTC is an optimized motor control method for AC drive systems, which allows direct control of motor torque and flux. In DTC, each switching instance is determined separately based on the values of actual flux and torque, rather than switching in a predetermined pattern as in conventional PWM flux vector drives.


Chapter 3 - Functional description, operation ABB

Figure 3-1 DTC block diagrams

The measured motor currents and DC link voltages are inputs to an adaptive motor model which calculates exact values of torque and flux every 25 μs. Motor torque and flux comparators compare the actual values to reference values which are produced by the torque and flux reference controllers.

Depending on the outputs from the hysteresis controllers, the optimum switching logic directly determines the optimum inverter switch positions every 50 μs. Switching takes place whenever required while in conven-tional Pulse Width Modulation (PWM) controlled drives switching is done only in predetermined patterns which results in slower response times.

3.2.1.2 DTC performance and benefits

DTC provides excellent speed control accuracy even without pulse encoder feedback. It virtually eliminates the excitation of any torque resonances on the motor shaft by avoiding explicitely assigned PWM modulation frequencies. Control of the frequency converter is immediate and smooth under all conditions and the audible noise in the motor is considerably reduced compared to other control methods.

Torque reference

Speed reference

Actualspeed

Speed control

Torquereferencecontroller

Torqueand fluxcomparator

Motor model

Switchinglogic

SwitchpositionsVoltage Current

Torque reference

Speed reference

Actualspeed &position

Speed control

Torquereferencecontroller

Torqueand fluxcomparator

- Motor model

Switchinglogic

SwitchpositionsVoltage Current

- Excitationcontrol

Asynchronous motor

Synchronous motor


54

ABB Chapter 3 - Functional description, operation

The torque response times are up to ten times faster than with conven-tional control methods such as current vector control. This results in minimum torque ripple and most accurate static speed and torque control.

DTC versus currentvector control

Table 3-1 DTC versus current vector control

Other DTC benefits Other major features and benefits of DTC are:

• High speed accuracy: typically 0.1% of nominal speed (without speed encoder)

• High torque performance

Full torque at zero speed and very fast torque step response time (typical ~ 3 milliseconds)

• Robust control method

DTC is extremely robust and compensates disturbances and inaccu-racies on supply, motor and load side. This avoids nuisance tripping and increases the reliability of the ACS 6000.

• Low audible motor noise and negligible low torque ripple by avoiding dedicated modulation frequencies

• Minimum inverter switching losses at maximum control performance.

Direct torque control (asynchronous motor)

Direct torque control (synchronous motor)

Vextor control

Motor control variables Switching is based on core motor variables flux

and torque

Switching is based on core motor variables flux

and torque

Switching is based on the separate control of

magnetic field and torque producing current compo-

nents

Requirements for speedencoder

Shaft speed and position are not required (only high performance applications

as for example in the mining and metal industry require speed encoders

Mechnical speed is essential. Requires shaft

speed and postion (measured or estimated)

Mechnical speed is essential. Requires shaft

speed and postion (measured or estimated)

Maximum inverterresponse time

Each inverter switching process is determined

separately (every 50 μs)

Each inverter switching process is determined

separately (every 50 μs)

Inverter switching is based on average references to a

pulse width modulator resulting in delays in

response and unnecessary switching

Torque step rise time Torque step rise time is less than 3 ms at 70%

speed

Torque step rise time is less than 3 ms at 70%

speed

Torque step rise time closed loop: 10 to 20 ms

sensorless: 100 to 200 ms



DTC provides fast control without requiring high switching frequency. This is possible because control is not based on a fixed PWM modulation frequency. Instead, switching takes place exactly when needed. Conventional PWM control would need >10 kHz switching frequency for equivalent performance.

DTC performance Figure 3-2 illustrates a typical dynamic speed response caused by a load step.

Figure 3-2 DTC: typical dynamic speed response

In many applications there is no need for speed and position encoders to meet the performance requirements. See Table 3-1 and Appendix - Technical data for detailed information.

The example in Figure 3-3 shows the response to a setpoint change. Torque response times can be reduced substantially if DTC is used instead of Pulse Width Modulation.

Figure 3-3 DTC vs. PWM: Typical torque response times

For more information on DTC, see Technical Guide No. 1 Direct Torque Control (3AFY 58056685 R0025).

PWM with encoder

DC drive with encoder

DTC with encoder

Static speed error ± 0.01 % ± 0.01 % ± 0.01 %

Dynamic speed error 0.3 % sec 0.3 % sec 0.2 % sec

Speed(rpm) Torque (kNm)

Time

Speed

Torque

Value depending on process

DTC

PWM

Torque:Typical torque step:response times at 70% speed• DTC: 3 ms• PWM flux vector: 10…20 ms• PWM: > 150 ms (scalar con-

trol)


54

A TC_ACS5000 Technical Data.pdf


3.2.2 Motor control functions

3.2.2.1 Speed control features

Accurate speed control The speed controller is based on a PID algorithm.

The steady state speed control error is around + 0.1% of motor nominal speed (without pulse encoder), which satisfies most industrial applica-tions.

The dynamic speed control error is typically + 0.2…0.5 % sec. at 100% torque step. The dynamic speed error depends on speed controller tuning.

Refer to Figure 3-2 for corresponding figures including pulse encoder.

Acceleration anddeceleration ramps

The converter provides user-selectable acceleration and deceleration ramps.

Figure 3-4 Typical ramp shapes

It is possible to adjust acceleration and deceleration times and to select different ramp shapes:

• S-curve ramps are ideal for applications, where a smooth transition from one speed to another is required.

• Linear ramps for converters requiring long acceleration/deceleration periods and where S-curve ramps cannot be used.

Accurate torque control By applying a torque reference instead of a speed reference, the converter maintains a specific motor torque value; the speed adjusts automatically to the required torque.

Speed and torque performance figures meet or exceed the requirements of IEC 61800-4.

Speed controllimitations

Parameter adjustable minimum and maximum limits can be set for speed and torque output.

3.2.2.2 Direct torque control features

Direct torque controlrelated settings

By setting the appropriate parameters, maximum and/or minimum limits can be defined for:

• Frequency

• Motor current

• Inverter overload

Max Speed reference

Speed referencechange limited bylinear rampSpeed referencechange limited byS-curve ramp

Ramp shape timeAccelerationtime

0



• Load angle

• DC voltage.

Motor model The motor model produces exact actual values of torque and flux, based on measured motor current and DC link voltages.

Excitation control The excitation current is controlled in a way that the power factor of synchronous motors is 1.

Speed and rotorposition

Rotor speed and position of a synchronous motor are monitored continu-ously to improve static and dynamic performance of the motor control loop.

As an option, a pulse encoder for speed monitoring is available for asynchronous motors.

3.2.3 Active rectifier control functions

DC voltage control The voltage of the DC link is stabilized by DC voltage control inside the active rectifier unit, minimizing the impact resulting from disturbances within the converter or the mains supply.

Reactive power control Reactive power control for the active rectifier unit is available as option. It is used to maintain a power factor of 1 in the mains supply. With reactive power compensation, cos ϕ can be controlled to any value within the range of +/- 0.8. The supply voltage level and supply voltage fluctuation have to be considered for the adaptation of the reactive power control.

3.2.4 Application control functions

3.2.4.1 Motor related functions

Load share control Load share control is used for applications with two separate motors where the shafts are coupled to each other by gearing, chain, belt, process etc. By means of load-share control the load can be evenly distributed between the drives.

3.2.4.2 Network related functions

Main circuit breakercontrol

The main circuit breaker should be closed by the converter only. This means that a closing request from the customer is sent to the ACS 6000. The actual closing command is then released from the converter to the main circuit breaker after charging the converter DC link capacitors.

All opening and closing commands to the main circuit breaker are monitored for time out. If the main circuit breaker does not change its status within a preset time, the main circuit breaker is tripped.

Preconditions for charging and for closing the main circuit breaker:

• No protection trip is active.


54


• No emergency off or stop is active.

• The DC bus grounding switch is open.

• Main circuit breaker must be in operating position (not in test position).

• All cabinet doors are closed.

• Water cooling unit is running and conductivity of the cooling water is within limits.

The close command from the converter to the main circuit breaker can be a continuous signal or a single pulse. If this status feedback does not arrive after a preset time, the close command is reset and the main circuit breaker is tripped.

Conditions for opening the main circuit breaker:

• Main circuit breaker open command (off command to active rectifier unit) is given either from local or from remote control.

• The emergency off is active (hardware signal or requested by the overriding control). The hardware signal directly activates the main circuit breaker tripping coil.

• A critical fault is detected by active rectifier unit or inverter unit.

• The emergency stop sequence is accomplished in an inverter unit and requests opening of the main circuit breaker.

If the open command from the converter to the main circuit breaker to open is a single pulse signal, it is reset upon receiving the status feedback "main circuit breaker OPEN" from the switchgear. If this status feedback does not arrive after a preset time, the tripping coil of the main circuit breaker is activated.

Several external main circuit breaker trip commands (e.g. transformer and motor monitoring relays, process trips, etc.) can be integrated into the hardwired tripping loop.

DC link control The DC link control monitors the DC voltage level at which main circuit breaker closing is enabled. It also monitors the DC voltage level at which the DC link is considered discharged and charging and discharging time outs.



3.3 Operation and diagnostics

3.3.1 Local and remote operationThe standard ACS 6000 provides all means for local and remote operation. Local operation is done by means of the local CDP control panel located on the front door of the control units and by two LED illumi-nated pushbuttons used for closing and opening the MCB (see also Chapter 6 - Control system and process interfaces, 6.3 Local control devices).

3.3.1.1 Selection of local or remote control mode

Selecting the local control mode is possible if no remote request from the overriding control system is present. The local control mode is set directly by pushing the LOC/REM pushbutton on the CDP control panel (See Chapter 6 - Control system and process interfaces, 6.3 Local control devices). An L on the panel display indicates local operation. In remote control, the L is not shown (see circle in Figure 3-5).

Figure 3-5 Setting the control panel to local / remote

Local control When the converter is switched to local control, local operation from the ON/OFF pushbuttons on the converter front door and from the CDP control panel is possible. In local operation mode no remote control command will be accepted.

Remote control When the converter is switched to remote control, local operation from the pushbutton on the front door of the control unit and from the CDP control panel is disabled. All commands like close/open main circuit breaker, start/stop or speed reference values are only received through the remote control interface.

Emergency off The local emergency off buttons on the front doors of the control unit(s) remain active in local and in remote mode.

Start and stopsequences

The converter can be started and stopped either manually from the local control panels or from remote overriding control.

1

StateINU

POWER Motor SP

0.0 rpm ReadyOn0 rpm

0.0 kW

->L 1

StateINU

POWER Motor SP

0.0 rpm ReadyOn0 rpm 0.0 kW

->


54


3.3.1.2 Start sequence

If all preconditions are fulfilled, the converter can be switched on by pressing the local ON button.

Each INU can be started individually via the local CDP control panel or from remote as soon as the DC link is charged.

Figure 3-6 Start sequence with ARU

RDY ON

RDY ON

Charge DC linkClose MCB

Start modulation

Start modulation

RDY RUN

RDY RUN

RDY REF

RDY REF Operation according

ARU control

- No fault- Aux supply on

- Grounding switch

Local: START

Remote:

Remote: RUN


- WCU ok- Doors closedNOT RDY ON

- MCB closed

(CDP ARU)

automatically

INU control

NOT RDY ON

- ARU RDY ON

ON (pushbutton)

Local: START (CDP INU)

Close EXU contactor (SD)

to setpoint

remote: ON

- etc.

...open



Figure 3-7 Start sequence with LSU

3.3.1.3 Stop sequence

Each INU can be stopped individually via the local control panel or via the remote control system.

The converter can be switched off by pressing the local OFF button.

RDY ON

Charge DC linkClose MCB

Start modulation

RDY RUN

RDY REF Operation according

- Gound switch open

Remote: RUN


- WCU ok

INU Control

NOT RDY ON

ON (pushbutton)

Local: START (CDP INU)

Close EXU contactor (SD)

to setpoint

- Doors closed

remote: ON

- etc.


54


Figure 3-8 Stop and off sequence with ARU

RDY REF

RDY REF

RDY ON

RDY REF

RDY RUN

RDY ON

Local: STOP (CDP INU)Remote: RUN

Ramp down speedStop modulation

Local: OFF(pushbutton)remote: OFF

(from master INU)

ARU control INU control

Open MCB (1st

Discharge DC linkStop modulation

Open EXU contactor (SD)

INU)



Figure 3-9 Stop and off sequence with LSU

3.3.1.4 Emergency off sequence

The converter is switched off immediately if the Emergency OFF button is pressed.

Figure 3-10 Emergency off sequence

RDY REF

RDY RUN

RDY ON

Local: STOP (CDP INU)Remote: RUN

Ramp down speedStop modulation

Local: OFF(pushbutton)remote: OFF

INU control

Open MCB (1st INU)

Discharge DC link

Open EXU contactor (SD)

RDY REF RDY REF

NOT RDY ON

Emergency OFF

Open MCB (1st INU)

Stop modulation

ARU control INU control

Coast ramp down

NOT RDY ON

Stop modulation Open EXU


54


3.3.2 Standard diagnostic functions

Actual signalmonitoring

Three signals can be displayed simultaneously on the control panel.

The most significant signals are:

• ACS 6000 output frequency, current, voltage and power

• Motor speed and torque

• DC link voltage

• Active control location (local / remote)

• Reference values

• Cooling water temperature, pressure and conductivity

• Digital I/O and analog I/O status.

Fault history The fault history contains information on the 64 most recent faults detected by the ACS 6000. Faults are displayed as a text message.

3.4 Standard protection functions

3.4.1 GeneralAll relevant system variables within the ACS 6000 are continuously monitored by the control system. Preprogrammed protection functions ensure that these variables remain within certain limits to maintain safe operation of the converter. These internal functions are not programmable by the user. Optionally, the ACS 6000 offers the processing of standard and customer specific fault signals from external equipment. They can be activated and adjusted by parameter settings.

If an alarm or fault condition occurs in the converter or related equipment, it will be indicated with an error message on the control panel or, as an alternative, on the DriveWindow error display.

Two error message levels are used in the ACS 6000:

• Alarm (warning): an alarm does not shut down the drive. However, a persisting alarm condition can often lead to a fault if the condition causing the alarm is not corrected.

• Fault: a fault always shuts down either the affected inverter or the whole drive. The type of shutdown depends on the origin of the fault.

Several fault classes are distinguished. In case of a fault in ARU, INU or an external device, the drive trips by blocking the IGCTs. In case of a severe internal fault, the ACS 6000 protects itself by turning on all switching devices simultaneously.

If an ARU initiates a trip, all INUs connected to the same DC bus trip as well and the main circuit breaker is opened.



If an INU initiates a trip, the main circuit breaker does not necessarily open. Depending on the severity and the type of fault, the main circuit breaker remains closed and only the affected INU trips (an overriding control system connected to the drive may stop the other INUs as well, if required).

3.4.2 Protection functions related to drive systemThe relevant system variables are monitored by the drive system related protection functions. The corresponding variables are calculated from the measurements supplied by the standard converter instrumentation:

Supply side protectionfunctions

• Undervoltage

The DC link voltage between DC(+) and DC(-) is measured on ARU and INU side. If the voltage drops below a preset level, an under-voltage trip is initiated.

• Overvoltage

Overvoltage protection is implemented both in software and in hardware for maximum reliability of the converter.

An overvoltage trip is initiated if the voltage in one of the DC links between DC(+) to DC(NP) and between DC(-) to DC(NP) rises above a preset level.

• ARU protection functions

If the converter is equipped with an active rectifier unit, the following protection functions are included:

• Network undervoltage (alarm and fault signals)

• Network overvoltage (alarm and fault signals)

• Network frequency deviation (alarm and fault signals).

Motor side protectionfunctions

• Motor stall

The stall protection function is used to prevent the motor and/or the inverter from overheating, or the motor from pulling out.

The converter protects the motor if a stall condition is detected. The monitoring limits for stall frequency (speed) and stall time can be set by the user. The user can also select whether the stall function is enabled and whether the converter responds with an alarm or a trip.


54


Figure 3-11 Stall region of the motor

The protection is activated if all of the following conditions are fulfilled simultaneously:

• Output frequency is below the set stall frequency.

• Actual torque exceeds stall torque limit (torque limit level can be set by the user).

• Frequency and torque levels from the previous condi-tions have been present for a period longer than the set stall time.

• Overspeed

Motor speed (as determined by the motor model) is monitored. If the motor speed exceeds a preset level, a trip is initiated.

• Overfrequency

If the frequency of a motor exceeds a preset level, the corresponding converter will trip.

• Motor phase loss

Inverter phase currents are monitored. In case of a phase loss, a trip is initiated.

• Overcurrent

Inverter phase currents are monitored. If a preset level is exceeded, a trip is initiated. This protection is implemented both in software and in hardware.

• Excitation protection

The excitation circuit of synchronous motors is protected against overcurrent, overload, supply network disturbance and earth fault (isolation measurement is used for earth fault detection).

• Ground fault

A ground fault is detected in two ways:

Stall region

Tm.a

f (Hz)Stall

Torque

frequency



• The neutral point voltage is monitored against ground. If the measured values are higher than the acceptable level, a trip is initiated.

• The sum of the inverter phase currents is monitored. If the result does not equal zero, a trip is initiated.

3.4.3 Internal converter protection functions

• Converter short circuit

A trip is initiated in case of a short circuit.

• Charging / discharging fault

The intermediate DC link voltage is monitored while charging and discharging the capacitors. If the voltage does not reach a certain level within a preset time frame, a fault signal is initiated.

• Neutral point voltage

The voltage in all three DC links is monitored for symmetry.

• DC Link short circuit

A trip is initiated in case of a short circuit.

• Printed Circuit Board (PCB) self monitoring

Cooling circuit Monitoring functions of the cooling circuit include the following:

• The status of the water cooling pumps and the water level in the expansion vessel (only open cooling circuits) are monitored.

• Temperature, pressure and conductivity of the cooling water are continuously measured and compared to preset limits. If a preset limit is exceeded, an alarm or (if the condition persists) a trip is initiated.

• The flow in the water treatment circuit is measured continuously. The reaction of the drive on insufficient flow can be set by parameter.

Communicationmonitoring

The status of all communication links is monitored. If a fault is detected, a trip is initiated.

3.4.4 External protection functionsInputs from additional external protection devices are monitored.

• Main circuit breaker

Inputs are provided for main circuit breaker monitoring functions (see also 3.2.4.2 Network related functions).

• Motor(s)

Optional inputs for group alarm and fault signals from motor and bearings are provided (optional customer interfaces, see Chapter 6 - Control system and process interfaces, 6.5 Hardwired process I/Os).


54


• Supply transformers

Optional inputs are provided for group alarm and fault signals (optional customer interfaces, see Chapter 6 - Control system and process interfaces, 6.5 Hardwired process I/Os).

3.4.5 Manually initiated protection functions

• Hardwired safety circuit

A hardwired safety circuit with redundant safety and timer relays monitors essential safety functions:

• Door interlocking

• Position of the grounding switches in the DC link

• Emergency off switch on the control cabinet door

• Manual emergency shutdown

The following inputs for manual emergency shutdown are provided:

• Emergency off: the main circuit breaker is opened immediately.

• Emergency stop: the motor is ramped down to zero speed as fast as possible and the main circuit breaker is opened.

• Process stop

An external process stop signal can be connected to a digital input. If the process stop input is opened, the motor is stopped. The type of stop (torque limit, ramp or coast stop) can be selected by parameter setting.

• Operation prevention

An external operation prevention signal can be connected to a digital input. If the input is opened, the motor cannot be started.

3.5 Other featuresConverter information The converter software version, the production date of the individual

version, and the serial number can be displayed.

Door interlocking The doors of the units containing medium voltage equipment (terminal sections, rectifier and inverter sections, capacitor banks) are equipped with an electromechanical interlocking system which ensures that the door of these units cannot be opened as long as the DC link of the converter is energized. For details refer to Chapter 4 - Hardware design, technology and configuration, 4.4 Cabinet design.

Parameter lock The user can prevent unwanted parameter adjustment by activating the parameter lock.



3.6 Optional featuresSee Chapter 10 - Options for information.


54

ABB

Chapter 4 - Hardware design, technology andconfiguration

4.1 OverviewThis chapter provides a description of the standard power, control and cooling hardware of the ACS 6000 including cabinet design, busbars and grounding, the auxiliary supply system and the cooling system.



• ACS 6000 Outline Drawings


• Appendix - Applicable codes and standards

4.2 Technology

4.2.1 Common DC busThe common DC bus connects all rectifier and inverter units on the DC side. While the common DC bus is well established with low voltage drives, the ACS 6000 has been the first drive to introduce the common DC bus principle to the medium voltage level.

4.2.1.1 Topology

The ACS 6000 is based on the voltage source inverter technology: the rectifier and inverter are connected to the same DC link capacitor (see Figure 4-1) and are built as modular units. Rectifier and inverter operation are decoupled. Therefore it is possible to connect more than one motor inverter and rectifier to the same common DC link. This way, the ACS 6000 can supply more than one motor or big motors.


OutlineDrawings_ACS5000.pdf


Chapter 4 - Hardware design, technology and configuration ABB

Figure 4-1 Common DC bus principle

Depending on the application, the following converter modules can be combined on the common DC bus:

• Active self-commutated 6-pulse Voltage Source Inverter (VSI)

This device allows four-quadrant operation and can be connected as Active rectifier unit (ARU) or inverter unit (INU). See Section 4.2.1.2 Active rectifier and inverter units.

• 6-pulse diode rectifier

for applications without power feedback to the line: Line Supply Unit (LSU).

4.2.1.2 Active rectifier and inverter units

The ARU and INU unit is a self-commutated 6-pulse, three-level voltage source inverter with IGCT technology:

• The ARU can operate in all four-quadrants and can be combined to 12-pulse or 18-pulse systems.

• Several INUs can be combined to supply higher power motors or to connect several motors to the same DC bus.

AC linevoltage

AC linevoltage

= =

= =

= =

=

=

Rectifier Inverter

Rectifier Inverter

Rectifier Inverter

Inverter

Inverter


68

ABB Chapter 4 - Hardware design, technology and configu-

Operating principle The ARU rectifies the transformer secondary AC voltage to the level of the DC link. The DC link voltage is kept constant by the ARU by drawing energy from the line when in driving mode and by feeding energy back to the line when in braking mode (see Figure 4-2).

Figure 4-2 Converter principle diagram

ARU and INU have identical design. Both circuits have an AC and a DC connection. The DC sides are connected to the DC link capacitor. Therefore the system is symmetrical.

In driving mode the ARU behaves like an INU in braking mode and vice verca as shown in Figure 4-4.

Control principle The ARU connects the three phases to DC (+), DC (NP) and DC (-) according to a certain pattern as in the example shown in Figure 4-3. The resulting ARU voltage patterns define the transformer secondary voltage. The transformer primary side is connected to the supply network.

Figure 4-3 Phase voltage created by ARU

Energy flow in driving mode

Energy flow in braking mode

ARU INU

AC linevoltage

DC linkvoltage

Voltage imposedby ARU

= =

U ARU

t



The voltage difference between transformer primary and secondary side is applied to the leakage inductance and determines the transformer current. The current can be controlled (see Figure 4-4) by varying phase angle and magnitude of the transformer secondary voltage.

Figure 4-4 Vector control principle

Power factor control By selecting an appropriate ARU pulse pattern, the transformer current will be in phase with the line voltage which means operation at unity power factor (cos phi = 1). This is the standard operation mode.

Optionally the power factor can be controlled between 0.8 leading and 0.8 lagging.

Optimized pulsepatterns

Since the ARU voltage pattern does not correspond to a sinewave, harmonics are induced in the voltage. To minimize the lowest harmonics, the pulse patterns are optimized. The optimized patterns are stored in a lookup table and the controller selects the correct pattern depending on the system conditions.

Control block diagram The ARU control block diagram is shown in Figure 4-5. Refer to Chapter 5 - Hardware design, description of converter units, 5.4 Active rectifier unit (ARU) for further details.

ARU

Ûtrans

Û1 ARUÛline

Ûtrans

Û1 ARUÛline

Îline

Ûtrans

Ûline

Îline

Û1 ARUϕARU

d

qBlock diagram

Equivalent circuit diagram Phasor diagram


68


Figure 4-5 Active rectifier control block diagram

4.2.1.3 Line supply unit

The Line Supply Unit (LSU) features a diode rectifier which is available in two versions:


• 12-pulse diode rectifier consisting of two standard 3-phase rectifiers

Using the configuration rules for the ACS 6000, LSUs with the same power rating can be operated in parallel to achieve 24-pulse rectification.

The LSU provides the following features:

• Two quadrant operation

• Operation at constant power factor of about 0.95

• Fuseless converter protection.

For further details on the LSU refer to Chapter 5 - Hardware design, description of converter units, 5.3 Line supply unit (LSU).

4.2.1.4 Advantages

Modularity The ACS 6000 modularity is based on the common DC bus principle. With the available INUs (3, 5, 7, 9 and 11 MVA) any motor or combination of motors in the range of 3 .. 27 MVA can be supplied.

Multi-motorconfigurations

Various combinations of synchronous and asynchronous motors are possible. The number of system components as well as the footprint can be reduced.

DC link voltage control

Modulator(optimizedpulse patterns)

Vectorcontrol

Meas.

Synchronization(PLL)

UAUBUC

Q ref

UDC ref

IA,B,C

UDC+ UDC-



By integrating more than one drive into one converter, the braking energy generated in one motor can be transferred to other inverters via the common DC bus without loading the rectifier.

4.2.2 Fuseless designThe ACS 6000, like all members of the ABB MV frequency converter family (ACS 1000, 2000, 5000 and 6000), does not require any power fuses which are known to be unreliable, costly and subject to aging.

Instead, the IGCTs of the inverter are used for protection. The IGCT provides a much faster and more reliable protection of the power compo-nents than fuses. In the event of an overcurrent, protection firing is triggered and the fault clearing is initialized in less than 25 μs, which is about 200 times faster than the cut-off time of a fuse. Avoiding the use of unreliable fuses results in better overall reliability.

4.2.3 IGCT power semiconductorThe Integrated Gate Commutated Thyristor is a power semiconductor switching device specifically developed for medium voltage converters. Based on well established GTO (Gate Turn Off Thyristor) technology, it enables intrinsically less complex, more efficient and reliable converter designs.

IGCTs combine high speed switching capabilities as known from IGBTs (Insulated Gate Bipolar Transistors) with high blocking voltage and low conduction losses as known from GTOs. See also Table 4-1.

Figure 4-6 IGCT


68


The IGCT combines the gate commutated thyristor together with the gate unit as integrated unit.

Table 4-1 IGCT technology compared to GTO and IGBT

4.3 Cabinet layoutThe modular design of the ACS 6000 allows the standardized converter units (e.g. LSU, ARU, INU, WCU) to be combined optimally for a specific application with minimum engineering effort.

Figure 4-7 and Figure 4-8 are examples for typical cabinet layouts. A detailed description of each unit is provided in Chapter 5 - Hardware design, description of converter units.

Figure 4-7 ACS 6000 basic configuration with LSU

GTO thyristor High voltage IGBT IGCT advantages

Switching technology High blocking voltage Low on-stste losses

High switching frequency Low switching losses

Snubberless

High blocking voltage High switching frequencyLow conduction losses

Snubberless

Equipment design Proven reliability Compact

Fuseless design

Modular design Proven reliabilityAllows compact and

modular equipment design Simple topologies with low

parts countSnubberless

LSU TEU/COU INU CBU WCU



Figure 4-8 ACS 6000 basic configuration with active rectifier and input filter unit

4.4 Cabinet design

4.4.1 Mechanical design

4.4.1.1 Basic design

The converter units are bolted and mounted on a base frame.

The cabinets are equipped with hinged doors.

The main control equipment is mounted on swing frames.

4.4.1.2 IP rating and sound pressure level

The standard cabinets are rated for IP 32. Ratings for IP 44 and IP 54 are available as option.

Sound pressure level is < 75 dB (A).

4.4.1.3 Transportation

Small converters with a length of up to 7 meters will be shipped as one unit. Bigger converters are separated into transportation units normally not exceeding a length of 5 meters.

All transportation units are fitted with lifting lugs and must be lifted to their position by crane.

4.4.1.4 Enclosure type and painting

Refer to Painting Specification (3BHS104301 ZAB E01).

ARU TEU/COU INU CBU WCUIFU VLU


68


4.4.1.5 Compliance with international standards

The design of the ACS 6000 fulfills the requirements of international standards listed in Appendix - Applicable codes and standards.

4.4.2 Electromagnetic compatibility (EMC)The inside of the cabinets is not painted to guarantee the electrical connection between the cabinet parts.

The joints between cabinet sections are bolted and EMC sealed. The cabinet doors and the internal cable trays are also equipped with EMC sealings.

4.4.3 Safety aspects

Door interlocking The medium voltage cabinets are equipped with an electromechanical interlocking system. The door locks are released if the safety grounding switch is closed and the auxiliary voltage is on. The doors are equipped with position switches. The safety grounding switch is released for opening only if all the doors are closed.

The doors of COU, EXU and WCU are not part of the interlocking system and may also be opened during drive operation.

Cabinet temperature The cabinet temperature is monitored by a thermostat.

Protective earth (PE) The PE busbar (protected earth) is installed through all cabinets (see 4.5 Busbars and grounding).

Cabinet labelling Danger areas are clearly marked with warning labels.



4.5 Busbars and groundingAC and DC power connections within converter cabinets are made with copper busbars.

Figure 4-9 Arrangement of busbars

AC busbars Incoming feeder and motor cables are connected to their corresponding busbars inside a TEU. In multi-motor drives several TEUs are part of the drive line-up.

The incoming busbars are interconnected with the line rectifier unit (ARU or LSU: depending on drive configuration) and the outgoing busbars with the motor inverter(s) (INU). The busbars can be identified by their phase designations.

DC busbars The DC busbars connect the line rectifiers (ARU or LSU) with motor inverter(s) (INU) and CBU. In multi-motor configurations up to four DC busbar arrangements can be installed. The busbars are mounted in the upper part of the converter and are marked with DC (+), DC (-) and DC (NP).

Safety ground It is important that the drive is properly grounded to maintain safety and to ensure smooth functioning of the equipment. For this reason, the drive’s grounding cable must be securely tied to the grounding system of the installation site (system ground).

The ACS 6000 is equipped with a continuous grounding busbar (marked PE, Protective Earth) which is installed through the length of the converter in the bottom area of the cabinets (see Figure 4-9).

The grounding cable must be connected to the grounding busbar of the converter at only one point: at the busbar inside the TEU closest to the CBU.The connection must be in compliance with local regulations.

Cable entry from top

Cable entry from bottom PG to PE connection in CBUConnecting point of system ground


68


Power ground Cable shields must be connected to the converter to ensure proper operation. A separate busbar (Power Ground, PG) is installed for this purpose. The busbars of power ground and protective earth are connected with each other inside the CBU which has the grounding switch mounted on the front door. The connection is made in the factory already.

4.6 Auxiliary supply systemThe total auxiliary power demand of the ACS 6000 includes

• auxiliary power for the cooling pumps and the charging unit and

• control power for the control hardware and the gate units

• optional auxiliary power for air-to-air heat exchanger.

The total auxiliary power can be supplied to the drive by a 3-phase AC power supply. Depending on the requirements for safe shutdown and the use of the ride-through functions of the ACS 6000, the control power must be supplied separately and backed up by an uninterruptible power supply (UPS). The ACS 6000 can be ordered with one of the following auxiliary power interfaces to accommodate these requirements:

• 3-phase supply

• 3-phase supply and separate UPS with AC output

• 3-phase supply and separate UPS with DC output

In addition, a separate power supply is needed for

• Each excitation unit if present in the line-up

• Optional converter space heaters (110 / 230 VAC).

4.6.1 3-phase supplyThe total auxiliary power is fed to the drive by a 3-phase supply with voltages between 380 and 690 VAC. If the power supply is interrupted drive internal capacitors provide a backup for the control hardware between 0.5 and 3 sec. enabling the drive to shut down in a controlled manner. Ride-through functions of the ACS 6000 are ineffective.



Figure 4-10 "AC safe line" auxiliary concept

4.6.2 3-phase supply and separate UPS for control powerThe control power is fed to the ACS 6000 separately from the 3 phase supply and backed up by a UPS. This has the advantage that the main control hardware will remain energized and the full ride-through capabil-ities of the ACS 6000 can be used. The control power interface of the ACS 6000 can be prepared for the following UPS voltage levels:

• 110 / 230 VAC (AC Safe Line), see Figure 4-11

• 110 / 220 VDC (DC Safe Line), see Figure 4-12

Figure 4-11 3-phase auxiliary supply and AC UPS

drive sectionsTo other

ChargingUnit

380 - 690 VAC (No safe line)

drive sections

To other

ChargingUnit

380 - 690 VAC110 / 120 / 230 VAC from ext. UPS (AC safe line)


68


Figure 4-12 3-phase auxiliary supply and DC UPS

4.7 Cooling systemThe ACS 6000 is equipped with a water cooling circuit for the main power components. Natural air convection inside the cabinets is used for cooling the control equipment and other components. Cooling pumps and heat exchanger are installed inside the WCU. The WCU is accessible for maintenance, even if the system is running.

In case of redundant configurations two separate water cooling circuits can be provided.

Refer to Chapter 5 - Hardware design, description of converter units for further details on the cooling system.

Figure 4-13 Principle diagram of the water cooling circuit

To other

drive sections

ChargingUnit

380 - 690 VAC110 / 220 VDC from ext. UPS (DC safe line)

Cooling pumps Heat exchanger




68

ABB

Chapter 5 - Hardware design, description ofconverter units

5.1 OverviewThis chapter provides a description of each individual unit. Detailed infor-mation is given on the cabinet layout, the available versions as well as on the monitoring and protection devices.





• Appendix - Applicable codes and standards

5.2 Available modulesThe following ACS 6000 units are available:

• Line Supply Unit (LSU), see section 5.3 Line supply unit (LSU)

6 and 12-pulse diode rectifier

• Input Reactor Unit (IRU), see section 5.3 Line supply unit (LSU)

For transformerless installations in combination with a 6-pulse LSU. IRU comprises the input reactor as a current limiter and a terminal section for the power supply cables.

• Active Rectifier Unit (ARU), see section 5.4 Active rectifier unit (ARU)

6-pulse self-commutated voltage source inverter

• Inverter Unit (INU), see section 5.5 Inverter unit (INU)

6-pulse self-commutated voltage source inverter for power ratings of 3 and 5 MVA with control part and power cable termination incorpo-rated in one cabinet.

6-pulse self-commutated voltage source inverter for power ratings of 7, 9 or 11 MVA (parallel connection for higher output power possible).

• Capacitor Bank Unit (CBU), see section 5.6 Capacitor bank unit (CBU)

Contains the DC link capacitors.

• Terminal Unit (TEU), see Section 5.7 Terminal unit (TEU)

For power cable termination.

• Control Unit (COU), see section 5.8 Control unit (COU)

• Water Cooling Unit (WCU), see section 5.9 Water cooling unit (WCU)




Chapter 5 - Hardware design, description of converter units ABB

• Customer Interface Unit (CIU), see section 5.10 Customer interface unit (CIU)

Houses additional input and output interfaces.

• Input Filter Unit (IFU), see section 5.11 Input filter unit (IFU)

Harmonic filter for ARU, use depends on supply network configu-ration.

• Voltage Limiter Unit (VLU), see section 5.12 Voltage limiter unit (VLU)

Dynamic DC voltage limiter

• Resistor Braking Unit (RBU), see section 5.13 Resistor braking unit (RBU)

DC chopper with integrated resistors

• Braking Chopper Unit (BCU), see section 5.14 Braking chopper unit (BCU)

DC chopper to be used in combination with external resistors

• Excitation Unit (EXU) see section 5.15 Excitation Unit (EXU)

6-pulse thyristor bridge or AC power controller

5.3 Line supply unit (LSU)

5.3.1 OverviewThe LSU rectifies the AC line voltage and supplies electrical energy to the DC link capacitors of the CBU (see section 5.6 Capacitor bank unit (CBU)). The available LSUs can be distinguished by pulse number and power rating.

5.3.2 12-pulse LSUThe 12-pulse LSUs as illustrated in Figure 5-1 are used in combination with a line-side converter transformer.


102

ABB Chapter 5 - Hardware design, description of converter

Figure 5-1 Cabinet layout of 12-pulse LSU

12-pulse LSUs are available for the following power ratings:

• 7 MVA

• 9 MVA

• 14 MVA

Cable duct and control section

di/dt limiting reactors

Rectifier monitoring

Diode stacks of

Snubber capacitor

Pulse transformer

Snubber resistors

Water inlet tube

Safety ground busbar

unit

(including crowbar)12-pulse rectifier



Using the configuration rules for the ACS 6000 (see Chapter 9 - Ordering information, 9.2 Drive selection), LSUs with the same power rating can be operated in parallel to achieve 24-pulse rectification and/or to increase the drive power.

5.3.2.1 Main components

The LSU consists of the following main components (refer also to Figure 5-2):


• Snubber circuit limiting the rate of the voltage rise (dv/dt) across the diodes and the crowbar thyristors

• di/dt limiting reactors defining the current rise in the thyristor crowbar

• Thyristor crowbar, a protection circuit which is activated should a short circuit occur in the converter. By applying protection firing the rectifier is shorted to prevent further damage of the converter.

• Pulse interface board generating the firing pulses sent to the crowbar thyristors via the pulse transmitters

• Diode rectifier monitoring unit for short circuit detection in the rectifier (indirect method to detect faulty rectifier diodes)

5.3.2.2 Circuit diagram

Figure 5-2 Circuit diagram of 12-pulse LSU

Thyristor crowbar di/dt choke

di/dt choke

Pulse interface board

Diode rectifier

To / from

DC (+)

RnpDC (NP)

DC (-)

INU

monitoring unit

Snubber circuitDiode rectifier

1L11L21L3

2L12L22L3


102


5.3.3 6-pulse LSUThe 6-pulse LSUs are designed for applications without converter trans-former and are always operated with a line-side Input Reactor Unit (IRU) as illustrated in Figure 5-3. The main purpose of the IRU is to limit the input current and to improve the Total Harmonic Distortion (THD) of the supply voltage.

IRU and 6-pulse LSU are available for the following power ratings:

• 5 MVA

• 7 MVA

Figure 5-3 Cabinet layout of 6-pulse LSU with IRU

5.3.3.1 Main components

The IRU/LSU consists of the following main components (refer also to Figure 5-4):

IRU • 3-phase input reactor

• Terminal section for input cables

LSU • 6-pulse diode rectifier

IRU LSU Terminal section

3-phase reactor

di/dt limiting reactors

Diode stacks of

(including crowbar)

Water inlet tubeSafety ground bar

Pulse transformer

Snubber resistors

6-pulse rectifier



• Snubber circuit limiting the rate of the voltage rise (dv/dt) across the diodes and the crowbar thyristors

• di/dt reactors limiting the current rise in the thyristor crowbar

• Thyristor crowbar, a protection circuit which is activated should a short circuit occur in the converter. The rectifier is shorted to prevent further damage of the converter by applying protection firing.

• Pulse interface board generating the firing pulses sent to the crowbar thyristors via the pulse transmitters

• Rectifier monitoring unit for short circuit detection in the rectifier (indirect method to detect faulty rectifier diodes)

5.3.3.2 Circuit diagram

Figure 5-4 Circuit diagram of 6-pulse LSU with IRU

5.4 Active rectifier unit (ARU)

5.4.1 OverviewThe ARU controls the energy flow to the DC link and keeps the DC link voltage at a constant level irrespective of changes in the supply network. The ARU is designed as a self-commutated voltage source inverter in 6-pulse, 3-level topology for the following power ratings:

• 7 MVA

• 9 MVA

• 9 MVA continuous (11 MVA/20 seconds every 60 seconds)

• 11 MVA (continuous operation)

Diode rectifier with snubber circuit

Thyristor crowbar

Diode rectifierMonitoring unit

di/dt choke

di/dt choke

Pulse interface board

DC (+)

DC (-)

To / from INU

1L11L21L3

IRU LSU


102


The units differ in their electrical ratings but have the same mechanical dimensions.

A maximum of three ARUs can be connected in parallel for drive power ratings up to 27 MVA resulting in 12-pulse or 18-pulse rectifier configura-tions.

Figure 5-5 ARU cabinet layout

Safety ground bar

Anti-saturation equipment

Phase modules

Gate unit supply

Water tubes

Voltage measurement



5.4.2 Main componentsThe ARU consists of the following main components (refer also to Figure 5-7 and Figure 5-8):

• Phase modules consisting of integrated gate commutated thyristors, diodes and clamp capacitors

The phase modules for all power ratings are identical in construction. The types of semiconductors used vary depending on the power rating. For this reason, phase modules for different power ratings cannot be mixed in the same ARU or INU.

Figure 5-6 Phase module with IGCTs

• Gate unit power supply (GUSP), an electrically isolated unit mainly supplying the IGCTs with auxiliary power

• Clamping circuit with di/dt chokes and freewheeling diodes protecting the circuit from excessive rises in current

• EMC filter protecting the transformer from excessive voltage slopes (dv/dt is limited to 1.7 kV/ms)

• 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. 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.

• Fast short circuit detection (FSCD) monitoring the main power circuit for short circuits

Antiparallel diodesIGCTsCooling water inlet

Cooling water outlet

Rear busbar stubs


102


• Anti-saturation equipment (ASE) preventing the converter trans-former from saturation

• Voltage and current measurement devices

The DC voltage is scaled on the High Voltage Divider board (HVD). The resulting signal and the signals from the AC current transducers are converted to digital signals on the Current and Voltage Measuring Interface board (CVMI) and transmitted to the Interface board via fiber optic cables.

Figure 5-7 ARU local control and monitoring equipment

5.4.3 Circuit diagram

Figure 5-8 ARU circuit diagram

L1,2,3

EMCfilters

GUSP

INT board

CMVIboard

FSCDboard

di/dt choke

di/dt choke

FSCDboard

Rclamp

Rclamp

DC (+)

DC (NP)

DC (-)

ASEboard

HVDboard

Gat

e fir

ing

puls

es

COU

Other INT

L1,2,3

DC (+)

DC (NP)

DC (-)

L 1L 2L 3

EMC filter (if without IFU) Phase modules Clamping circuit



5.5 Inverter unit (INU)

5.5.1 OverviewThe INU converts the DC voltage to the AC motor voltage. The self-commutated, 6-pulse, 3-level voltage source inverter allows four-quadrant operation.

The available INUs are distinguished by their power rating and design.

The compact 3 and 5 MVA units as illustrated in Figure 5-9 with the vertical alignment of the inverter phase modules have their Control Unit (COU) and the Terminal Unit (TEU) for the motor cables incorporated in different sections of the same cabinet.

Refer to sections 5.8 Control unit (COU) and 5.7 Terminal unit (TEU) for further information on COU and TEU.

Figure 5-9 3 and 5 MVA Units

The bigger 7, 9 and 11 MVA units as presented in Figure 5-10 have the same layout and components as the Active Rectifier Unit (ARU) except for the anti-saturation equipment which is not needed for motor operation. Refer to 5.4 Active rectifier unit (ARU) for details.

Depending on the application, up to five INUs with different power ratings can be connected to the same DC bus.

Phase modules of

Control unit (COU)

Terminal unit (TEU)behind control unit

the inverter


102


Figure 5-10 7, 9 and 11 MVA INUs


Figure 5-11 Circuit diagram of 7, 9 and 11 MVA INUs

Phase modules

DC (+)

DC (NP)

DC (-)

L 1L 2L 3

EMC filterPhase modulesClamping circuit



Figure 5-12 Circuit diagram of 3 and 5 MVA units

5.6 Capacitor bank unit (CBU)

5.6.1 OverviewThe CBU smoothes the intermediate DC voltage and decouples the rectifier from the inverter. The CBU contains DC link capacitors, a charging unit and a grounding switch.

The CBU is available in two different sizes depending on the power rating of the converter (size 1 for converters up to 9 MVA and size 2 for converters rated for 9 to 14 MVA).

For high power converters, up to two CBUs of the same size can be installed on the same DC link.

5.6.2 Main componentsThe CBU consists of the following main components (refer also to Figure 5-13):

• Water-cooled DC link capacitors

• Charging unit for the DC link capacitors consisting of an auxiliary transformer and a small diode rectifier

The capacitors are charged before the converter is connected to the main power source to avoid excessive inrush currents after the main circuit breaker has been closed.

• Optional discharging unit, needed to discharge the DC link capacitors when the converter is shut down and none of the following units are part of the ACS 6000 converter:

• Voltage Limiting Unit (VLU)

• Resistor Braking Unit (RBU)

DC (+)

DC (NP)

DC (-)

EMC filterPhase modulesClamping circuit

L 1L 2L 3


102


• Braking Chopper Unit (BCU)

• Grounding switch, a safety switch to ground the DC bus of the converter

The grounding switch can only be closed if the DC link capacitors have been discharged.

• Optional coupling device for monitoring the insulation resistance

Figure 5-13 CBU cabinet layout

Cable duct

DC busbars

DC link capacitors

Water inlet tubeSafety ground busbar

Grounding switch

Dummy capacitor

Charging unit

Connection PE - PG




Figure 5-14 CBU circuit diagram

5.7 Terminal unit (TEU)

5.7.1 OverviewMains and motor cables of the ACS 6000 converter are connected to their corresponding busbars inside Terminal Units (TEU). TEUs are designed for top or bottom cable entry.

TEUs are available either as separate cabinets or they are integrated into other cabinets. The number and type of TEUs present in a line-up depends on the type and the power ratings of the line rectifier (LSU or ARU) and the power ratings of the motor inverter (INU):

• The TEU for 5 and 7 MVA, 6-pulse Line Supply Units (LSU) is incor-porated into the cabinet of the Input Reactor Unit (IRU) (see Figure 5-3).

• The TEU for 3 and 5 MVA Inverter Units (INU) is built into the same cabinet as the inverter (see Figure 5-9).

• The TEU used in combination with 12-pulse LSUs and power ratings of 7, 9 and 14 MVA and in combination with INUs/ARUs and power ratings of 7 and 9 MVA shares a separate cabinet with a Control Unit (COU). See Figure 5-15 and Figure 5-16 (Figure 5-15 shows the Terminal Unit with the swing frame of the Control Unit opened).

The width of the cabinet (600 mm or 1000 mm) is determined by the number of line rectifiers and/or motors to be supplied via one TEU. If required by the configuration of the ACS 6000, cabinets without a Control Unit can also be present in the line-up.

Capacitors Charging unit

Grounding switch

PE

DC(+)

DC(NP)

DC(-)


102


• Separate TEU for 11 MVA continuous power INUs (no combination with other units).

Figure 5-15 TEU (1000 mm wide)

5.8 Control unit (COU)

5.8.1 OverviewThe COU incorporates the hardware for control, monitoring and protection functions of the line rectifier or the inverter it is assigned to. The COU also includes the interfaces to the local control panel on the front door and to a higher-level process control system.

Power cable entry section (bottom)

AC busbars

Safety ground

Power ground

Ground terminals

busbar

busbar

Swing frame of Control Unit (COU) open

Ground terminals

for grounding set

for grounding set

Phase designation

Roxtec frame



Figure 5-16 COU control swing frame installed in a TEU (typical configu-ration)

S800 I/O modules

Safety relays of emergency off circuit

Timer relays*

INU operation prevention

Auxiliary relays*

Circuit breaker forcharging transformer

Miniature circuit breakers*

230 VAC socket

24 VDC power supply units

devices*

Auxiliary power supply equipment*

Position (gray) encoder

Speed encoder interface*

Main circuit breaker

24 VDC distribution terminals

control board

Auxiliary relays for maincircuit breaker control

Insulation monitor*

Thermostats for:

cabinet temperaturecabinet fan unit

Synchronizing equipment for ARU**

230 VAC distribution

Auxiliary contactors

terminals

* option, depends on the configuration of the frequency converter ** only converters with ARU (Active Rectifier Unit)

PE busbar

interface*


102


Figure 5-17 Reverse side of COU doors (typical configuration)

Fan unit

Branching unit*

Branching unit*

INT board**

AMC board***

INT board****

AMC board

2

Local control panel

24 VDC distribution

Fan unit

1

Pocket fordocumentation

* option, depends on the configuration of the frequency converter** only converters with parallel ARUs (Active Rectifier Unit)*** only converters with ARU (Active Rectifier Unit) ****only converters with two INUs supplying a motor

(see section 6.5.1 for details)

terminals

Redundant drive interface*

2121



The hardware components of a COU are mounted on a swing frame. The type and number of the fitted components are determined by the configu-ration of the ACS 6000. The size of the swing frame and the mounting position of the components depend on the cabinet the swing frame is installed in. See Figure 5-9 for the illustration of the swing frame in 3 and 5 MVA Inverter Units and Figure 5-16 for the illustration of the swing frame in a TEU.

The number of COUs in a line-up depends on the configuration of the ACS 6000:

• A separate COU is assigned to an ARU in combination with 3 and 5 MVA INUs.

As a standard, an ARU in combination with 7, 9 and 11 MVA INUs shares the COU of the first INU. Depending on the selected options and the configuration of the converter, a separate COU is used for the ARU.

When a LSU is part of the converter, all rectifier and line related functions are implemented in the COU of the first Inverter Unit as well.

• A separate COU is assigned to each INU supplying its own motor.

Several INUs supplying one motor share the same COU.

5.8.2 Main componentsThe COU consists of the following main components (refer also to Figure 5-16and Figure 5-17):

• AMC board, a digital signal processor for controlling line rectifier and motor inverter(s). See Chapter 6 - Control system and process inter-faces, 6.2.1 Hardware for more information.

• S800 I/O modules, standard I/O devices connecting converter related hardwired signals to the AMC controller

• Control panel, a door-mounted user interface for local operation. See Chapter 6 - Control system and process interfaces, Control panel for more information.

• Optional speed and position encoders (gray encoder)

• Auxiliary power supply. See Chapter 4 - Hardware design, technology and configuration, 4.6 Auxiliary supply system for more information.


102


5.9 Water cooling unit (WCU)

5.9.1 OverviewThe heat losses from the main power components are dissipated to the exterior by the water cooling system of the converter (see section 5.9 Water cooling unit (WCU)).

Additionally, depending on the power demand of the converter, roof-mounted air-to-air heat exchangers are used to remove the heat from non-water cooled components inside the power sections of the converter (see section 5.9.9 Air-to-air heat exchangers).

5.9.2 Water cooling systemThe main power components e.g. rectifier bridges, inverter phase modules, DC link capacitors, resistors are cooled by a closed-loop water cooling system.

Figure 5-18 Principle illustration of water cooling circuit

The WCU is equipped with two pumps and a water-to-water heat exchanger. Deionized / distilled water is circulated continuously dthrough the components to be cooled to a water-to-water heat exchanger which transfers the heat to an external cooling circuit. The cooling unit is acces-sible for maintenance, even if the converter is in operation.

Water cooling circuits The water cooling system consists of three circuits:

1. The internal circuit filled with deionized / distilled water transfers the heat losses of the main power components to the water-to-water heat exchanger in the WCU.

2. The water treatment circuit is part of the internal circuit and continu-ously purifies the cooling water of the internal circuit to keep the conductivity at a low level. The circuit also includes a fill-up valve.

3. The external water circuit containing raw water transfers the heat losses from the water-to-water heat exchanger to the exterior.



5.9.3 WCU types and sizesWater cooling units are available in two designs:

• Closed to atmospheric pressure (see Figure 5-19 and Figure 5-20)

This type of cooling unit is used in converters with lower power demand. The closed circuit is equipped with a pressurized expansion vessel and is mainly used in marine applications and in applications requiring frost-proofing of the internal circuit with a glycol water mixture.

• Open to atmospheric pressure (see Figure 5-21 and Figure 5-22)

Water cooling units with open circuit are used in converters with a higher cooling demand.

The size of the WCU present in a converter is determined by the required cooling capacity.

5.9.3.1 WCU closed to atmospheric pressure

Figure 5-19 WCU - closed to atmospheric pressure

Cable duct

Water pumps

Heat exchanger

Ion exchange vessel

Control swing frame


102


Figure 5-20 Principle flow diagram of a WCU with a closed circuit

1

2

3

4

5

6

7

8

Expansion vessel

Deaerationvessel

Make-up waterISO-R 1/2

Drain hoseØ12

1 from converter pipe DN 80 5 outlet to cooler counter flange DN 50 / ANSI 2"

2 from EXU hose nipple Ø 26.5 6 inlet from cooler counter flange DN 50 / ANSI 2"

3 to EXU hose nipple Ø 26.5 7 raw water outlet counter flange DN 50 / ANSI 2"

4 to converter pipe DN 80 8 raw water inlet counter flange DN 50 / ANSI 2"



5.9.3.2 WCU open to atmospheric pressure

Cabinet layout

Figure 5-21 WCU open to atmospheric pressure

Cable duct

Water pumps

Heat exchanger

Ion exchanger vessel

Swing frame


102


Flow diagram

Figure 5-22 Flow diagram of WCU with open circuit

5.9.4 Main componentsThe WCU consists of the following main components (see also Figure 5-19, Figure 5-21 and the flow diagrams in Figure 5-20 and Figure 5-22):

• Swing frame containing mainly the auxiliary power supply switch, the pump motor starters and digital and analog I/O interfaces for control and monitoring of the water cooling cicuit.

Factory-fed auxiliary power unit supplying the converter internally with the required auxiliary voltages. See Chapter 4 - Hardware design, technology and configuration, 4.6 Auxiliary supply system for an overview of the auxiliary distribution circuit.

1

2

3

4

5

6 8

7

Drain hose Ø 12

Drain hose Ø 12

Drain hose Ø 12Make-up water

ISO-R 1/2

1 thread ISO-Rp 1/2 5 to EXU hose nipple Ø 26.5

2 from converter pipe DN 80 6 to converter pipe DN 80

3 from EXU hose nipple Ø 26.5 7 raw water outlet counter flange DN 80 / ANSI 3"

4 thread ISO-Rp 1/2 8 raw water inlet counter flange DN 80 / ANSI 3"



• Control and monitoring devices for temperature, pressure and conductivity of the internal cooling water

• One water pump circulating the water through the internal cooling circuit, one standby pump

• Water-to-water heat exchanger transferring the heat from the internal cooling circuit to the external raw water circuit

• Expansion vessel for pressure compensation

• Water conditioning circuit with ion exchange vessel purifying the cooling water of the internal circuit and thus maintaining the water conductivity at the desired low level

• Three-way valve controlling the flow through the heat exchanger

• Optional hardwired process I/O interfaces. SeeChapter 6 - Control system and process interfaces, 6.5.1 Standard S800 I/O modules for more information.

5.9.5 Cooling controlControl and monitoring functions of the WCU are included in COU1. The I/O interfaces for these functions are mounted on the swing frame of the Control Water Unit (CWU) inside the WCU. The I/O interfaces are linked to the main controller (AMC board) where all control and monitoring functions regarding the water cooling system are implemented. The actual values of temperature, pressure and conductivity of the internal cooling water are continuously transferred to the main controller where they are monitored for alarm and trip levels.

Pump control Parameter settings allow to run either one of the two pumps continuously or both pumps in programmable intervals. The latter setting corresponds to the default setting.

Independent of the selected operating scheme of the pumps, a pump is started automatically, as soon as the auxiliary power of the ACS 6000 is switched on and no emergency-stop signal is present. After the pump has started, monitoring of the water pressure is enabled after a short delay.

Auto-cooling sequence The cooling system can be started automatically, when the auto-cooling sequence is selected. This feature is useful to decrease the water conduc-tivity automatically after a longer shutdown of the converter. If enabled, the water conductivity is monitored and a water pump is switched on if the conductivity has increased above a programmable threshold. The pump circulates the water through the deionizer vessel thus decreasing the water conductivity. When the water conductivity is below the alarm level, the pump is switched off after a parameter adjustable delay. The sequence is repeated as soon as the water conductivity increases again above the starting threshold of the pump.


102


When both pumps are selected to run and the running pump fails, the pump in standby is automatically switched on. Isolation valves allow the decommissioned pump to be disconnected from the water cooling circuit and serviced during converter operation.

Three-way valve The three-way valve controls the flow through the heat exchanger and is opended or closed depending on the internal water temperature. The valve ensures that the water flow in the external circuit remains constant whereas at the same time the flow through the water-to-water heat exchanger varies depending on the required cooling water.

5.9.6 Raw water connectionThe raw water pipes are connected to the WCU with two flanges which are part of the supply. The feeding and return pipe can either be entered through the top or the bottom. Back and side entry is only possible with a 800 mm WCU. The desired pipe entry is specified when ordering the converter.

Instead of the rigid pipe connection, the WCU can also be ordered for flexible water connections.

5.9.7 Technical dataSee Appendix - Technical data, section Cooling for a detailed list of parameters of the water cooling system and options regarding extended raw water temperature and pressure.

5.9.8 Options for WCURefer to Chapter 10 - Options, 10.2 Options for WCU.

5.9.9 Air-to-air heat exchangersConverters with high output power demand are additionally equipped with roof-mounted heat exchangers, which ensure a constant air flow through the power sections thus transferring the heat from non-water-cooled components to the exterior. The fans of the heat exchangers are controlled by thermostats and are switched on when the air temperature exceeds the adjusted starting threshold of the fans.

The auxiliary transformer on the roof is installed only if the converter is equipped with heat exchangers (see Figure 5-23).



Figure 5-23 Roof heat exchangers

5.10 Customer interface unit (CIU)

5.10.1 OverviewThe Customer Interface Unit houses optional I/Os to monitor transformer and motors of multi-motor drives. The following units are available:

• CIU1 provides a set of predefined I/Os. The I/O modules are connected to an AMC controller.

• CIU2 and CIU3 comprise the same set of I/O modules as CIU1 and a programmable AC 80 / AC 800 controller. In addition to CIU2, unit CIU3 includes the software programming as well.

• CIUe provides engineered project specific interfaces.

Optional I/Os for transformer and motor monitoring functions for single-motor drives are integrated into the customer interface unit (CIW) inside the WCU.


102


Figure 5-24 CIU, typical cabinet layout

5.10.2 Main componentsThe CIU consists of the following main components:

CIU1 • Five additional I/O modules (S800 modules) with predefined I/Os for auxiliaries of each motor

• Predefined I/Os for transformer auxiliaries

CIU2, CIU3 • Five additional I/O modules (S800 modules) and programmable AC 80 / AC 800 for auxiliaries of each motor

• I/Os for transformer auxiliaries

• Control panel(s)

CIUe • Customer specific I/O configuration



5.11 Input filter unit (IFU)

5.11.1 OverviewThe IFU reduces harmonic voltages injected to the supply network and is used in combination with 6-pulse ARUs connected to a weak supply network. The IFU is a tuned filter located between the converter trans-former and the ARU.

If an IFU is part of a converter line-up, the continuous power of the ARU is approximately 8.2 MVA / 50 Hz and 7.0 MVA / 60 Hz.

Figure 5-25 IFU cabinet layout

5.11.2 Main componentsThe IFU consists of the following main components:

• Decoupling reactors in the main circuit

• Filter reactors

• Filter capacitors

• Damping resistors

Filter resistors

Filter capacitors


102



Figure 5-26 IFU circuit diagram

5.12 Voltage limiter unit (VLU)

5.12.1 OverviewThe VLU dynamically discharges the DC link capacitors to the normal level should an overvoltage occur. Discharging takes place by a set of casted resistors which are switched on by IGCTs (see Figure 5-28).

The VLU is used in applications (typically metals and mining) requiring dynamic changes between motoring and braking modes.

The ratings of the VLU depend on the size of the converter.

L 1 TEU

L 2 TEU

L 3 TEU

L 1 ARU

L 2 ARU

L 3 ARU

IFUTEU ARU



Figure 5-27 VLU cabinet layout

5.12.2 Main componentsThe VLU consists of the following main components:

• Resistors, protected against overload by means of a software based thermal model.

• VLU short circuit detection (VLSCD). Feedback signals from the VLSCD are used to monitor the correct switching of the IGCTs.

Air-cooled resistors

IGCTs


102



Figure 5-28 VLU circuit diagram

5.13 Resistor braking unit (RBU)

5.13.1 OverviewThe RBU is used in drive applications where fast braking is required but regenerative braking is not possible (e.g. marine applications). Typically, the RBU is part of an ACS 6000 with a Line Supply Unit (LSU).

The RBU is available for a braking power of 0.5 to 0.8 MW and a total energy dissipation of 10 MWs per braking cycle. The energy generated during braking is dissipated in a set of water-cooled resistors which are switched on and off by IGCTs (see Figure 5-30). When utilizing the full braking capability, a cool-down phase of 20 minutes between two braking cycles is necessary. The braking power can be doubled by adding a cabinet with another set of resistors.

VLU

INU

VLSCDboard

VLSCDboard

DC (+)

DC (NP)

DC (-)

INT-Board



Figure 5-29 RBU cabinet layout

5.13.2 Main componentsThe RBU consists of the following main components:

• Water-cooled resistors, protected against overload by means of a software based thermal model

• RBU short circuit detection (VLSCD). Feedback signals from the VLSCD are used to monitor the correct switching of the IGCTs.

IGCTs

Water-cooled resistor


102



Figure 5-30 RBU circuit diagram

5.14 Braking chopper unit (BCU)

5.14.1 OverviewAn ACS 6000 can be equipped with a BCU when effective motor braking and short deceleration times are required but regenerative braking is not possible (e.g. ACS 6000 with LSU).

The BCU houses the braking chopper hardware and the busbar termi-nation for the braking resistor cables and is connected to the DC bus.

The BCU is available for various sizes and types of external braking resistors. The resistors are dimensioned based on the required braking power (up to 2.3 MW) and energy. The resistors connected to the positive (1 in Figure 5-31) and negative DC voltage (2 in Figure 5-31) must have identical electrical ratings.

5.14.2 Main componentsThe BCU consists of the following main components:

• Braking chopper with IGCTs, diodes and snubber circuit

• Terminals for external braking resistors

• BCU short circuit detection (VLSCD). Feedback signals from the VLSCD are used to monitor the correct switching of the IGCTs.

RBU

INU

VLSCDboard

VLSCDboard

DC (+)

DC (NP)

DC (-)

INT-board




Figure 5-31 BCU circuit diagram

5.15 Excitation Unit (EXU)The Excitation Unit (EXU) is delivered as part of the frequency converter when a synchronous motor has to be supplied with excitation power.

Excitation units are available in an air-cooled and a water-cooled version for the two excitation methods of the synchronous motor:

• Brush excitation (DC excitation)

• Brushless excitation (AC excitation)

BCU

INU

VLSCDboard

VLSCDboard

DC (+)

DC (NP)

DC (-)

External brakingresistors

INT-board

1

2


102

ABB

Chapter 6 - Control system and process inter-faces

6.1 OverviewThis chapter provides a description of the control hardware and software of the ACS 6000, as well as the hardwired and fieldbus interfaces that are at the customer’s disposition. Furthermore, the available control options are explained as well.



• Standard and Optional I/O Configuration (3BHS123187 ZAB E01)

6.2 Hardware and structure of the control systemThe control system of the ACS 6000 is designed in a decentralized structure to support the modular design of the drive optimally and to ensure fast and reliable data and signal transfer between the individual converter units. Identical hardware (e.g. main controller and interface boards for fiber optic communication) is used for control, monitoring, measurement and protection functions on line and on motor side. However, a board of the same type can be equipped with different software depending on the function the board fulfils.

The structure of the control system is adapted to the configuration of the ACS 6000 and mainly determined by the type of the line rectifier (LSU or ARU) and by the number of the Inverter Units (INUs). Thus, the control-hardware structures of different configurations are mainly distinguished by the number of installed controller and interface boards as described and illustrated in the following. Some typical basic hardware structures are shown in Figure 6-2 and Figure 6-3.

6.2.1 Hardware

AMC controller The control system is based on ABB’s well proven Application and Motor Controller (AMC). Fitted with a 150 MHz Motorola DSP processor, the controller features two PPCS and eight DDCS communication channels. PPCS (Power Plate Communication System) and DDCS (Distributed Drive Control System) are acronyms for serial communication protocols tailored for data transfer via fiber optic cables, namely with:

• Converter and excitation control interfaces

• Higher-level process control systems via advant or fieldbus adapters, see section 6.4 Fieldbus interfaces

• I/O devices, see section 6.5 Hardwired process I/Os

• Service tools (e.g. DriveWindow), see Chapter 10 - Options.


Chapter 6 - Control system and process interfaces ABB

Configuration rules The number of AMC controllers used in the control system depends on the configuration of a converter:

• A separate AMC controller is installed in a converter with a single Active Rectifier Unit (ARU), or in a converter with a group of ARUs connected in parallel (see Figure 6-1).

This line-side AMC controller is not part of the control system if the converter is equipped with a Line Supply Unit (LSU) (see Figure 6-3).

• An additional AMC controller is used for each Inverter Unit (INU) supplying its own motor, or a group of INUs supplying one motor (see Figure 6-4 and Figure 6-6).

Control units The line-side AMC controller and the AMC controller of the first INU are mounted in the same Control Unit (COU). In multi-motor drives this is always COU1. The line-side AMC controller is installed separately (COU0), when the converter is equipped with an ARU in combination with 3 and 5 MVA INUs.

The AMC controller of each additional INU supplying its own motor is mounted in its own Control Unit.

The control units of a multi-motor line-up are serially numbered and can be identified by their COU name plates. The location of the COUs in the project specific line-up can be seen in the mechanical drawings.

Control panel An AMC controller is always connected to a CDPcontrol panel which is mounted on the front of the corresponding COU. The CDP control panel serves as a basic user interface for monitoring, control and operation and changing of parameters. The communication of the AMC controller with the CDP control panel is accomplished via a RS-485 link. For detailed information on the functions of the CDP control panel, refer to 6.3 Local control devices.

INTerface boards AMC controllers communicate with each other through an INTerface board (INT) which incorporates a software (Power Feed Forward [PFF]) for optimized data transfer.

The same type of INT board serves as a branching unit between an AMC controller and the INT boards of ARUs connected in parallel, or between an AMC controller and the INT boards of INUs supplying one motor. For this purpose, a software is utilized which facilitates data branching (PPCS Unit for Branching [PUB]).

INT boards for these communication links are located inside the first COU.

Data between an AMC controller and the control hardware in ARU or INU are exchanged through INT boards as well. An additional board is mounted in each ARU and INU.


124

ABB Chapter 6 - Control system and process interfaces

General control tasks General control, protection and monitoring tasks regarding the whole converter are always implemented in the AMC controller of the first INU (also referred to as Master INU). These tasks include control and monitoring of:

• Main Circuit Breaker (MCB)

• Grounding isolator / charging unit

• Door interlocking

• Water cooling

Excitation unit If an INU controls a synchronous motor, the reference value for the excitation current is provided by the AMC controller associated to the INU. The excitation current controller is implemented on the CCB board located in the Excitation Unit (EXU). Signals between AMC controller and CCB board are transmitted via fiber optic cables (see Figure 6-2 for illustration).

6.2.2 Configuration examplesIn the following, simplified examples are presented which point out the use of the AMC controller and the interface boards in different converter configurations.

Single-motor drive withARU

Single-motor drives have a separate AMC controller for ARU and INU making the control of the ARU independent from the INU.

Data between the AMC boards is transmitted via an INT board containing a communication software for optimized data transfer. Both AMC controllers and the INT board are located on the same swing frame of the COU.

The communication between the line-side AMC controller and the ARU as well as the communication between the motor-side AMC controller and the INU takes place through INT boards which are installed in the ARU and the INU respectively.

Figure 6-1 Single-motor drive with ARU

AMC AMC

INTINT

INT

COU

ARU INU



The following Figure 6-2 provides a detailed view of the interconnection of the control hardware of a Control Unit, an Active Rectifier Unit and an Inverter Unit.

Figure 6-2 Single-motor drive with ARU (example with water-cooled EXU)

Single-motor driveswith LSU

When equipped with a LSU instead of an ARU, all rectifier and line related functions of the ACS 6000 are implemented in the AMC controller of the COU (COU1 in multi-motor drives) assigned to the first INU.

The following Figure 6-3 illustrates how the control hardware of a single-motor drive with a LSU is interconnected.

Rectifier control Inverter control

Pro

cess

I/OPC tool PC tool

Rotor speed

Rotor position

Fieldbusadapter

RS 485

Control panel

ABBadvant

Control panel

ABBadvant

Excitationsupply

Process controlsystem


FT-link

COU

ARU INU EXU

AMC AMC

SYN INT

NTAC

GRB

VA...VC

IA...ICIA...IC IDC vDC

CCB MUB

PAI MUI

GDR

INT INT

HVD + CVMI HVD + CVMI

V DC

+

V DC

-

V NP to

gro

und

V DC

+

VD

C-

VN

P to

gro

und

RS 485

control control

Fieldbusadapter


124


Figure 6-3 Single-motor drive with LSU

Multi-motor drive withARU

In addition to the single-motor drive described before, a further AMC controller for the second INU is added to the control system in a separate COU2. With each additional INU added, the control system is basically extended by another control unit which is equipped with an AMC controller, and by an INTboard and the inverter control hardware located in the inverter.

Proc

ess

I/O

PC tool

Rotor speed (optional)

Fieldbusadapter

Control panel

ABB

To NTAC (optional)

Inverter control


(optional)

FT-link

Diode monitoring

COU

S800

AMCNTAC

LSU INU

PINT

EAF

INT

HVD + CVMI

IM

PG

FSC

DFS

CD

PPC

S

PP

CS

IOC

VD

C+

V DC

-

V NP to

gro

und

IA...IC

advantcontrol



Figure 6-4 Multi-motor drive with ARU

Multi-motor drive withdouble ARU

As illustrated in Figure 6-5, multiple ARUs are controlled by only one AMC board which communicates with the line rectifiers via the same type of INT board as used for the communication between the AMC boards in the examples above.

Figure 6-5 Multi-motor drive with double ARU

Single-motor drive withdouble ARU and

double INU

The example below shows that double INUs supplying one motor also require only one AMC controller which communicates with the inverter units via the same type of INT board as the AMC controller assigned to the line rectifiers.

Figure 6-6 Single-motor drive with double ARU and double INU

COU1 COU2

INT

INT INT INT

ARU INU1 INU2

AMC AMCAMC

ARU1 ARU2 INU1 INU2

INT INT INT INT

INT

AMC AMC AMC

COU1 COU2

COU

AMC AMC

ARU1 ARU2 INU1 INU2

INT INT

INTINTINTINT


124


6.3 Local control devices

6.3.1 CDP local control panelThe ACS 6000 is equipped with a CDP control panel, the same panel as used for ABB's low voltage frequency converters family. The CDP is an intelligent digital control panel with function keypad and LCD display. It provides full control of the frequency converter and allows adjustment of the system parameters.

The key features of the CDP control panel are:

• 4-line display for easy monitoring,

• user selectable display of actual values, such as motor speed, current, voltage, torque, power,

• fault memory to support maintenance.

The panel allows the operator:

• to enter startup data into the drive,

• to control the drive by setting reference values and by giving start, stop and direction commands,

• to display three actual values at a time,

• to display and set parameters,

• to display information on the last 64 fault events.



Figure 6-7 CDP control panel

6.3.2 CDP control panels, control switches and indicator lampsCDP control panels of the same type are used for the line-side ARU and for local operation of the motors on the INU control units.

The ARU control panel is installed on the door of control unit COU1 (see Figure 6-8). Converters with LSU do not have this control panel.

The CDP control panel for the first inverter unit (INU1) is mounted on the door of control unit COU1 (see Figure 6-9). The on/off switches for the main supply are also installed on the door of COU1 (see Figure 6-9).

The number and location of additional CDP control panels (see Figure 6-10) depends on the configuration of the converter (e.g. single or multi-motor drive, drive for motors with double windings). The arrangement of the CDP control panel and the switches on the doors of the associated control units is the same for all units.

Stop button

Mode selection buttons

Alphanumeric display(4 lines x 20 characters)

Enter button

Start button

Setpoint setting button

Forward, reverse buttons

Local, remote button

Reset button

Selection and changing buttons


124


The bulbs of lamps and illuminated pushbuttons can be tested with the lamp test function. The lamp test is activated via the CDP control panel by setting a control parameter.

An emergency off switch is installed on each contol unit. The emergency off switches affect the whole drive when activated (see Figure 6-9 and Figure 6-10).

The grounding switch is installed on the capacitor bank unit (CBU). The switch can only be actuated if released by the converter (see Figure 6-11). When the grounding switch is released, the indicator lamp on the door of the CBU lights up. The indicator lamp has an integrated momentary pushbutton to test the lamp. The lamp lights up when the pushbutton is pressed.

Figure 6-8 ARU control panel

Control Panel- displays ARU status messages- displays ARU alarm and fault

- resets alarm and fault messages..messages



Figure 6-9 INU control panel

Control panel- starts and stops the motor- displays status messages of the

- displays alarm and fault messages- resets alarm and fault messages

Illuminated pushbuttons- OFF opens the main cicuit breaker- ON closes the main cicuit breaker

Alarm / fault lamp - ALARM: flashing light- FAULT: permanent light

Emergency off reset switch

Emergency off switch- prevents starting when actuated

- main circuit breaker opens and

during operationEMERGENCY OFF

at standstill

DC link discharges when actuated

converter


124


Figure 6-10 Control panel on additional control units

Alarm / fault lamp - ALARM: flashing light- FAULT: permanent light

Emergency off switch- prevents starting when actuated

- main circuit breaker opens and

during operation

at standstill

DC link discharges when actuated

Control panel- starts and stops the motor- displays status messages of the

- displays alarm and fault messages- resets alarm and fault messages

converter



Figure 6-11 Grounding switch on CBU

6.4 Fieldbus interfaces

6.4.1 Fieldbus typesFieldbus interfaces are used for the serial, bidirectional communcation between the converter and a higher-level process control system. Using fieldbus interfaces, the converter can be controlled and status messages, reference and actual values can be transmitted. Detailed information on data transmission and on data and signal allocation to the transmitted datasets can be obtained from the "Signal and Parameter Table" and from the "Installation and Start-up Guide" of the installed fieldbus adapter.

Table 6-1 Fieldbus adapters

A fieldbus adapter is mounted on the swing frame of a control unit and is directly connected to an AMC controller via fiber optic cables.

If the converter is equipped with several AMC controllers, as in multi-motor drives, data are not transmitted via a single fieldbus interface. Owing to the modular structure of the converter, the higher-level control system communicates directly with each AMC controller. Each AMC controller is connected to a separate fieldbus adapter.

Grounding switch, grounds the converter

Indicator lamp with lamp test function- signals when grounding switch can be turned

into position “grounded” - used to test the lamp. Lamp lights up when

cap is pressed

Fieldbus Adapter typea

a. Other fieldbus adapters are available on request

AF 100 fieldbus communication interface ABB FCI

Profibus DP NPBA-12

Modbus NMBA-01

Modbus+ NMBA-01

Ethernet NETA-01

DDCS Drive Bus CI858 (external adapter)


124


6.4.2 SignalsCommunication with the AMC controller is accomplished with datasets, each containing 3 x 16 bit integers. Each dataset contains a standardized set of process data. The content of the datasets must be programmed accordingly in the remote process controller.



Note: The following tables are for general information only and should not be used for engineering purposes. The project relevant signal and parameter tables depend on the final drive configuration and on the selected control and communication hardware.

Table 6-2 Basic data exchange between AMC and process control: analog and binary inputs

Input types

Target Value Description

Word INU Reference 1, speed reference in rpm

Word INU Reference 2, torque reference

Bit 0 INU/ARU

1

0

Command to close MCB

Command to open MCB

Bit 1 INU/ARU

1

0

-

Emergency OFF command (coast stop + MCB off)

Bit 2 INU/ARU

1

0

-

Emergency STOP command (emergency stop ramp)

Bit 3 INU 1

0

Command for state "Ready Reference"

Normal stop (current controller is blocked)

Bit 4 INU 1

0

Normal operation

Ramp generator output is set to zero (torque stop)

Bit 5 INU 1

0

Enable speed ramp

Speed ramp is stopped, actual setpoint is frozen

Bit 6 INU 1

0

Enable setpoint

Ramp generator input is set to zero (ramp stop)

Bit 7 INU/ARU

1

0

Fault reset (rising edge)

-

Bit 8 INU 1

0

Accelerate to inching speed reference 1

Stop inching (brake as fast as possible)

Bit 9 INU 1

0

Accelerate to inching speed reference 2

Stop inching (brake as fast as possible)

Bit 10 1

0

AC 80 / AC 800 controller requests to control the drive

No control from remote

Bit 11 1

0

Select external control location 2

Select external control location 1

Bit 12 1

0

-

Process stop requested


124


Table 6-3 Basic data exchange between AMC and process control: analog and binary outputs

Output type

Target Value Description

Word INU Actual speed in rpm (integer: 20000= max. speed). Used by the speed controller

Word INU Actual torque (integer: 10000= nominal torque)

Bit 0 INU/ARU

1

0

Drive ready for ON command (ready to close MCB)

Not ready

Bit 1 INU/ARU

1

0

Drive ready for RUN command

Not ready

Bit 2 INU/ARU

1

0

Drive ready for reference value

Operation inhibited

Bit 3 INU/ARU

1

0

Drive tripped

No fault

Bit 4 INU/ARU

1

0

-

Emergency OFF active (coast stop + MCB off)

Bit 5 INU 1

0

-

Emergency STOP active (emergency stop ramp)

Bit 6 INU/ARU

1

0

Switching ON is inhibited

-

Bit 7 INU/ARU

1

0

Alarm or warning is active

-

Bit 8 INU/ARU

1

0

Setpoint and actual value within margins

Actual value differs from setpoint

Bit 9 INU/ARU

1

0

Drive controlled by overriding control system

Drive controlled via CDP panel or DriveWindow

Bit 10 INU/ARU

1

0

Actual speed equals or exceeds limits

Actual speed within limits

Bit 11 INU/ARU

1

0

External control location 2 selected

External control location 1 selected



6.5 Hardwired process I/Os

6.5.1 Standard S800 I/O modulesInternal and external I/O signals are connected to the ACS 6000 control system by standard ABB Advant S800 I/O modules. The I/O modules are installed in the COUs. The external I/O signals are connected to terminals inside the WCU and are internally wired to their I/O modules.

An S800 I/O station consists of up to 12 I/O modules and a TB 820 bus modem serving as an interface to the corresponding AMC controller. Each I/O module is plugged into a module termination unit containing the S800 module bus.

The number of S800 I/O stations per converter depends on the configu-ration of the ACS 6000.

Figure 6-12 S800 I/O station

Table 6-4 S800 I/O modules

I/O module type No. of channels I/O rating

Digital input DI 810DI 811

1616

24 VDC48 VDC (on request only)

Digital output DO 810DO 820

168 relays

24 VDC230 VAC

Analog inputAI 810AI 820AI 830

848

0(4)...20 mA, 0(2)...10 V,0(4)...20 mA, 0(2)...10V, +/- 20 mA, +/- 10 VPT100 resistance measurement

Analog output AO 810AO 820

84

0(4)...20 mA, 0(2)...10 V,0(4)...20 mA, 0(2)...10V, +/- 20 mA, +/- 10 V

TB 820 bus modem

TU 830 termination unit

Digital output moduleDigital input module

TU 831 termination unit


124


TB 820 bus modem Communication between an AMC controller and I/O modules is accom-plished by a bus modem via a fiber optic link using the standard DDCS protocol. Data between a bus modem and I/O modules is transmitted through the S800 module bus.

Figure 6-13 S800 I/O configuration of an ACS 6000 single drive

6.5.2 Customer control signalsThe complete list of standard and optional customer control signals is provided in Standard and Optional I/O Configuration (3BHS123187 ZAB E01).

6.5.3 Interface configurations

6.5.3.1 General

The ACS 6000 can be integrated into all common industrial control environments. Typically, it is connected to the process control system via a fieldbus interface. The standard ACS 6000 provides all hardwired I/O signals to protect itself. Optional I/Os can be provided to monitor the trans-former and the motor.

6.5.3.2 I/O configurations for single-motor drives

The following three I/O configurations are possible:

• Standard configuration

The standard configuration includes the converter related functions (i.e. interface to the MCB) and the local control panel.

TB 820 TB 820

AMC controller

DDCS

CH 7

S80

0 m

odul

e bu

s

S80

0 m

odul

e bu

s

S80

0 m

odul

e bu

s

DI 810

DO 810

DI 810

DO 820

DI 810

DO 820

AI 820

AI 820

DI 810

AO 820

DO 820

AI 820

WCUCOU1

TB 820

standard standard option CIW1



• Option CIW1

This option provides additional five S800 I/O modules with predefined I/Os for transformer and motor auxiliaries.

• Option CIW2 and CIW3

This option provides a programmable AC 80 / AC 800 controller and the same I/O configuration as option CIW1.

Additionally, the five I/O modules can be replaced by other S800 modules. These I/Os can be allocated to specific functions depending on the user’s needs.

The resulting optional signals are listed in section Chapter 10 - Options, 10.5 Optional customer interfaces.

Figure 6-14 ACS 6000 single-motor drive with option CIW1

6.5.3.3 I/O configurations for multi-motor drives

The following four I/O configurations are possible:

• Standard configuration

The standard configuration includes the converter related functions (i.e. interface to the MCB) and the local control panel.

Fieldbus (e.g. Profibus)

Fieldbus (e.g. Modbus)

Service tool (*)e.g. DriveWindow

Fieldbus adapters (*) Control

panel

AMC processor

Position /speedencoder (*)

Inverter/MCB/Emergency off/charging

WCUmonitoring

CustomerI /O (*)

(*) optional equipment

CIW1 (option)

Standard I/O

ARU/LSU)

CBU INU TEU /COU WCU

S800 S800

S800(*)


124


• Option CIU1

The hardware of this option corresponds to option CIW1. The five predefined S800 I/O modules are placed in a separate cabinet (see Chapter 5 - Hardware design, description of converter units, 5.10 Customer interface unit (CIU)).

• Option CIU2 and CIU3

Options CIU2 and CIU3 correspond to option CIW2 and CIW3. S800 I/O modules and AC 80 / AC 800 are mounted in a separate cabinet (see Chapter 5 - Hardware design, description of converter units, 5.10 Customer interface unit (CIU)).

• Option CIUe

This option is used for engineered interfaces. The additional I/O modules are placed in a separate cabinet (see Chapter 5 - Hardware design, description of converter units, 5.10 Customer interface unit (CIU)).

The resulting optional signals are listed in section Chapter 10 - Options, 10.5 Optional customer interfaces.

Figure 6-15 Typical ACS 6000 multi-motor drive with option CIU2



Programmingtool (*)

Fieldbus (e.g. Profibus)

Fieldbus (Modbus)

Fieldbus adapters (*)

Fieldbusadapters (*)

Fieldbus adapters (*)

AMC processor AMC processor AMC processor

Inverter 1 / MCBEmergency off /Charging

WCUmonitoring

CustomerI / O (*)

CustomerI / O (*)

CustomerI / O (*)

Inverter 2 I/O Inverter 3 I/O

(*): optional equipment

Position/speed

encoder

Position/

encoderspeedPosition/

speedencoder

CDPcontrolpanel

CDPcontrolpanel

CDPcontrolpanel


CIU2 CIU2 CIU2



6.6 Control software

6.6.1 Control software structureThe control software is adapted to the modular design of the ACS 6000 hardware and is organized into the following functional groups (see Figure 6-16):

• Operating system software (AMCOS)

• Rectifier and inverter control software

• Fixed application software

• FCB application software for configurable functions

Figure 6-16 Software block diagram of the AMC controller

INU control AMC

AMCOS (AMC Operating System)

AMCOS (AMC Operating System)

AMC

Function blocklibrary

Function blocklibrary

Panel application

Panel application

Motor control +Fixed application

Speedcontroller

Direct torquecontroller

AMC table

Modulatorinterface

Modulatorinterface

DC voltageand cosϕ controller

AMC table

Rectifier control

Fixed application

Magnetizationreference to EXU

Fieldbus adapter

Advant ACcontrollerS800 process I/O

Control panel

Fieldbus adapter

Advant ACcontroller

Control panel

FCB

applicationprogram

ARU control

+

applicationprogram

FCB


124


6.6.2 Operating systemThe AMC Operating System (AMCOS) is a real-time multitasking system providing functions such as task scheduling and FLASH memory management as well as standardized interfaces to the AMC table and services for I/O communication and diagnostics.

The AMC table contains data for motor, rectifier and application control functions including the process I/O image. The AMC table serves also as an interface for data interchange between different software groups.

6.6.3 Motor and rectifier control softwareThe control software for motor and rectifier includes control algorithms which provide optimum performance in conjunction with IGCTs:

• Direct Torque Control (DTC), the motor control method for highest torque and speed performance

• Vector control with optimized pulse patterns for the Active Rectifier Unit (ARU).

6.6.4 Fixed application softwareThe fixed application software includes fault handler, main state machine, speed controller and functions for fast communication and master follower applications.

Fault handler The fault handler classifies each detected event and allocates each regis-tered fault to one of several predefined fault classes. The fault classes, defined separately for Active Rectifier Unit and Inverter Unit(s), determine if the main circuit breaker opens in case of a fault or not. Upon an event, the fault handler updates the fault logger and the alarm and fault words of the AMC table and accesses the Main State Machine (see description below) which in turn coordinates the reaction of the drive. The following events are distinguished:

• Alarm

An alarm does not shut down the drive. However, a persisting alarm condition can often lead to a fault if the condition is not corrected.

• Fault

A fault always shuts down either the affected inverter or the whole drive. The type of shut-down depends on the origin of the fault. Faults are divided into

• Faults with low priority (drive shuts down after a long delay)

• Faults with high priority (drive shuts down after a short delay)

• Faults with immediate shut down of the drive



Main state machine The Main State Machine (MSM) is a predefined program serving as the prime control place for drive control systems based on the AMC controller. The MSM is called up cyclically by the operating system and coordinates start, stop and fault sequences in ARU and INU. It determines the optimum reaction on any event or fault occurring in the converter.

6.6.5 FCB application software The application software which is also implemented on the AMC controller is programmed with the Function Chart Builder (FCB), a graphical PC software tool. The FCB makes use of a function block library which consists of a selection of preprogrammed (cannot be changed by customer) software blocks.

The application software contains:

• I/O handling routines

• Customer and drive interfaces

• Selection logic for reference and control location

• Fault and alarm monitoring

• Drive operation sequences and interlocking

• Auxiliary device control

6.6.6 Panel application softwareThe panel application software exchanges information between the AMC table of an AMC controller and the control panel connected to it.

The panel application software provides also the PC interface to DriveWindow.

6.7 Control optionsSee Chapter 10 - Options for information.


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ABB

Chapter 7 - Engineering information

7.1 GeneralThis chapter describes the requirements for system components which are not included in the converter scope of supply. Further information on the requirements for system components are available in the following system component specifications:




• Specification for Main Circuit Breaker (3BHS125149 ZAB E60)

• Requirements for Main Feeder and Transformer Protection (3BHS125149 ZAB E81)

• ARU Main Transformer Specification (3BHS125092 ZAB E01)

• Technical Requirement Specification (12-pulse LSU for single drives) (3BHS121185 ZAB E01)

• Technical Requirement Specification (24-pulse LSU) (3BHS121186 ZAB E01)

• Selection of Synchronization Transformers for ACS 6000 (3BHS125393 ZAB E01)

• ACS 6000 Asynchronous Motor Specification (3BHS211284 ZAB E01)

• ACS 6000 Asynchronous Motor Specification for non-ABB machines (3BHS 211984 ZAB D01)

• Metals Induction Motor Specification (3BHS254644 ZAB D01)

• ACS 6000 Synchronous Motor Specification (3BHS217607 ZAB E01)

• Metals Synchronous Motor Specification (3BHS254140 ZAB D01)

• ACS 6000 Power Cables Specification (3BHS125090 ZAB E01)

• Wiring and Busbar Specification (3BHS205465 ZAB E01)

7.2 Main circuit breaker The main circuit breaker is one of the most important protection devices of the whole fuseless designed drive system.

The main circuit breaker should preferably be a SF6-gas insulated circuit breaker or a vacuum type breaker. The main circuit breaker has to be specified according to the rated primary voltage and current of the trans-former and shall comply with IEC Publication 56 and ANSI c37.09.



Chapter 7 - Engineering information ABB

Refer also to Specification for Main Circuit Breaker (3BHS125149 ZAB E60) and Requirements for Main Feeder and Transformer Protection (3BHS125149 ZAB E81).

7.3 Main transformerThe ACS 6000 converter is fed from a main transformer providing suffi-cient impedance to limit line harmonics and short circuit currents to acceptable levels. Oil immersed or dry type transformers can be used. Between main transformer and converter a maximum cable length of 300 m (984 ft.) is allowed.

7.3.1 Main transformer for ARURefer also to Main Transformer Specification (3BHS125092 ZAB E01).

7.3.2 Main transformer for LSURefer also to Technical Requirement Specification (12-pulse LSU for single drives) (3BHS121185 ZAB E01) and Technical Requirement Speci-fication (24-pulse LSU) (3BHS121186 ZAB E01).

7.4 ARU synchronization transformerRefer also to Selection of Synchronization Transformers for ACS 6000 (3BHS125393 ZAB E01).

7.5 Asynchronous motor requirementsAsynchronous motors used in combination with ACS 6000 are squirrel cage induction motors. Insulation requirements are higher than for motors used in direct-on-line operations. For their thermal design the harmonic content in the motor current has to be taken into consideration.

Refer also to ACS 6000 Asynchronous Motor Specification (3BHS211284 ZAB E01), ACS 6000 Asynchronous Motor Specification for non-ABB machines (3BHS211984 ZAB E01) and Metals Induction Motor Specification (3BHS254644 ZAB D01).

7.6 Synchronous motor requirementsSynchronous motors used in combination with ACS 6000 are Salient Pole synchronous motors. Insulation requirements are higher than for motors used in direct-on-line operations. For their thermal design, the harmonic content in the motor current has to be taken into consideration.

Refer also to ACS 6000 Synchronous Motor Specification (3BHS217607 ZAB E01) and Metals Synchronous Motor Specification (3BHS254140 ZAB D01).


128

ABB Chapter 7 - Engineering information

7.7 Excitation supplyThe voltage for the excitation system is supplied by a separate feeder transformer (3-phase 400 VAC, as option: 690 VAC). Transformer ratings depend on the motor data.

In case of multiple motors, one common medium to low voltage trans-former can be used for several excitation units. In this case, a separate feeder transformer must be added for each excitation unit in order to provide sufficient commutation inductance according to Figure 7-1.

Figure 7-1 Excitation transformer schemes for multi-motor drives

7.8 Selection of power cables

7.8.1 Power cable dimensioningThe following aspects have to be considered when dimensioning power cables:

• Loading of cables

• Specifications of the cable manufacturer.

• Method of installation

• Voltage drop due to cable length

• Local regulations.

The drive specific cable requirements are described in the following sections.

EXU EXU EXUEXU EXU EXU

Excitation supplyExcitation supply

Option A: Option B:


Chapter 7 - Engineering information ABB

Refer also to ACS 6000 Power Cables Specification (3BHS125090 ZAB E01).

7.9 Control cabling Control cables Control cables should be provided in accordance with Table 7-1. Cable

shields should be terminated on the ACS 6000 side only. Either single or multiple twisted pair cables may be used.

Table 7-1 Control cable requirements

Synchronization cables Synchronization cables are not applicable for ACS 6000 with line supply unit. A 3-phase shielded cable without neutral wire is required for the voltage supply of the synchronization transformer. For information on ratings contact ABB.

Cable marking Refer also to Wiring and Busbar Specification (3BHS205465 ZAB E01).

Signal type General cable type Cross-section

Analog input Twisted pair(s) - overall shield 0.5 to 2.5 mm2 / AWG 20 to AWG 12

Analog input Twisted pair(s) - overall shield 0.5 to 2.5 mm2 / AWG 20 to AWG 12

Digital input Twisted pair(s) - overall shield 0.5 to 2.5 mm2 / AWG 20 to AWG 12

Digital output Twisted pair(s) - overall shield 0.5 to 2.5 mm2 / AWG 20 to AWG 12

Speed encoder Twisted pair cable with separately shielded pairs and overall shield

0.5 mm2 4 x (2+1)

Position encoder Twisted pair cable with separately shielded pairs and overall shield

0.5 mm2 4 x (2+1)


128

ABB

Chapter 8 - Installation guidelines

8.1 GeneralThis chapter provides all necessary instructions for transportation, requirements for the installation site as well as for the mechanical and electrical installation material.





• Roxtec Cabinet Seals

8.2 Ambient conditionsAmbient conditions may require to derate the drive due to the presence of increased air temperature, cooling water temperature or altitude. Suffi-cient air flow must be available. Other ambient factors such as relative humidity, air contamination, shock and vibration must also be in compliance with stated maximum permissible levels.

See Appendix - Technical data for load capacity derating factors and other requirements related to ambient conditions.

Converter enclosure The standard IP protection classes for the converter enclosure according to IEC 60529 are given in Chapter 4 - Hardware design, technology and configuration, 4.4.1.2 IP rating and sound pressure level.

8.3 TransportTransport units Each transport unit is mounted on a base frame. The base frame is a

permanent fixture.

The maximum length of the base frame is 5.7 m. The length of the transport units is specified in the quotation.

The converter can also be shipped devided into individual modules (without base frame) if the space for installation is limited. The final converter alignment remains unchanged.

Lifting and moving Transport sections of a converter must always be lifted by crane with the cabinets in upright position. The lifting cables should be fixed to the cabinets and be at an angle as indicated in Figure 8-1 to Figure 8-3.




Roxtec Cabinet Seals.pdf


Chapter 8 - Installation guidelines ABB

Figure 8-1 Cabinets with base frame and without door handles

Figure 8-2 Cabinets with base frame and marine-type door handles

Figure 8-3 Cabinets without base frame

30°Protectedges !

30°

MAX.120°

Cable angleindicated on cabinet roof


140

ABB Chapter 8 - Installation guidelines

8.4 Installation site requirementsFoundation and floor

levellingCabinets must be installed in upright position.

The floor must be of non-flammable material, with a smooth and non-abrasive surface, protected against humidity diffusion, levelled and able to support the weight of the converter (min. 1’000 kg/m2).

Dimensions The length of the ACS 6000 depends on the configuration (number and type of modules). The height (2200 mm) and depth (1000 mm) are the same for all configurations. The exact dimensions of the line-up are stated on the mechanical drawings supplied with the drive.

Clearances ABB recommends a minimum free space of 400 mm behind and on both sides of the converter for installation, service and repair purposes as well as for cooling purposes (see Figure 8-4).

The free space above must not be less than 700 mm for installation, cooling and explosion protection purposes.

A minimum free space of about 1600 mm is recommended in front of the converter as an escape route. However, this distance might vary depending on local regulations.

Figure 8-4 Space requirements (dimensions in mm)

The dimensions in Figure 8-4 do not include space for cable and water entries (top and bottom entries possible). Dimensions must be specified when ordering the ACS 6000.

Recommended 400 mm or more



The lengths of typical drive configurations are given in Appendix - Technical data.

Cable trays and holes Cable trays must be of non-flammable material with non abrasive surface.

Holes in the floor or in the wall(s) have to be prepared for planned cable and cooling water pipe penetrations (according to the final layout drawings).

A protection against fire spreading, humidity, dust and penetration by animals must be forseen.

Ventilation A part ot the heat losses are dissipated into the air. For this reason, the installation site must be ventilated to fulfill the requirements for ambient conditions as specified in Appendix - Technical data. The heat losses into the air depend on the power rating of the converter.

Safety aspects Sufficient illumination of the electrical room has to be forseen (typically 100 lux with white fluorescent lamps) for safety reasons.

Local safety regulations must always be considered (e.g. door locks for electrical room).

8.5 Raw water flangesThe incoming and outgoing raw water pipes are connected to the flanges inside the water cooling unit. The pipes can be entered through the bottom or the side of the water cooling unit.

Installation material such as counter flange, bolts, nuts and seals are part of the supply. The flanges provided are as illustrated in Figure 8-5.


140


Figure 8-5 Flanges

8.6 Power cable installation, grounding and shieldingThis chapter describes the minimal requirements for power cable instal-lation, grounding and shielding. Additional requirements in local regula-tions have to be considered.

8.6.1 Sealing system for power cable entryThe power cable entry of the converter is prepared for the use of the modular Roxtec sealing. The system seals the cable transits of the converter against electromagnetic disturbances and provide the required IP protection.

The cable entry assembly for the power cables consists of a galvanized entry frame. The frame holds the adaptable EMC sealing modules. The modules can be easily adapted to the cable diameter, simply by peeling off the concentric layers of the module. Compression wedges ensure that the conductive foil of the sealing modules tightly enclose the cable armor or shield in the area of the cable transit.

The sealing modules are not part of the delivery.

Dimensions are in mm (in)

DN 65

ANSI B16.5 150 lbs 2.5



Figure 8-6 Power cable entry with roxtec sealing system

8.6.2 Connecting ARU to supply transformerFigure 8-7 shows an installation with 3 cables running in parallel. The total cable diameter is defined by the power consumption of the drive.

Frame

Sealing module

Compression wedge

Conductive foil

Removable layers to adapt the

Sealing module

sealing module to the cable diameter


140


Figure 8-7 ARU side cabling

a) with 3-core cables b) with single-core cables

Feeding transformer or busbar

Feeding transformer or busbar

TEU TEU

ACS 6000 ARU ACS 6000 ARU

16 mm2< A < 50 mm2

(Cu)Armor

Shield16 mm2< A < 50 mm2

(Cu)



8.6.3 Connecting LSU to supply transformer

Figure 8-8 LSU side cabling

Feeding transformer

TEU

ACS 6000 LSU

(Cu)

Armor

Shield

16 mm2< A < 50 mm2

Equipotential bonding


140


8.6.4 Connecting motor to INU

Figure 8-9 INU side cabling

8.7 Equipment groundingThe grounding cable must be connected to the grounding busbar (marked PE, Protective Earth) of the converter at only one point: at the busbar inside the TEU closest to the CBU. The connection must be in compliance with local regulations.

a) with 3-core cables b) with single-core cables

ACS 6000 INU ACS 6000 INU

TEU TEU

16 mm2< A < 50 mm2

(Cu)

Armor

Shield

Motor Motor

Equ

ipot

entia

lbo

ndin

g

16 mm2< A < 50 mm2

(Cu)



Figure 8-10 TEU, connection to system ground

8.8 Installation of auxiliary power and control cablesThe cable entry for auxiliary and control cables is prepared for the use of the Roxtec sealing system.

Figure 8-11 Control cable entry with roxtec sealing system

Protective Earth (PE)to be connected tosystem ground

CS F 16 frame

Sealing inserts

a b

c d

e f


140


The cable entry plate is furnished with a Roxtec frame, type CS F 16, which holds the sealing modules. These can be selected individually depending on the number, type and diameter of the cables. The frame has an integrated compression gasget and for this reason needs no separate compression wedge for keeping the cables in place.

Information on dimensions and exact location is stated on the project specific layout drawing.

Sealing module "a" in Figure 8-11 is part of the delivery.




140

ABB

Chapter 9 - Ordering information

9.1 GeneralThs chapter provides assistance in selecting the appropriate drive and the included options.




• ACS 6000 Type code (3BHS128455 ZAB E01)

9.2 Drive selection

9.2.1 Required application dataABB selects the appropriate converter configuration in accordance with the following main data:

• Mains nominal frequency fn and short circuit power

• Number and type of connected motors, ratings of each motor (rated power Pn, peak power Ppeak, braking capability, nominal, minimum and maximum speed, number of poles)

• Type of application and other geographic and climatic requirements (ambient temperature range, humidity, altitude of installation etc.).

Specifications The basic drive configuration and dimensioning is done by ABB sales based on the customer’s specification of the application and by using specialized configuration tools.

The following specifications must be completed by the customer in order to provide the required application data:

See Chapter 7 - Engineering information for further requirements and information.

9.2.2 Configuration procedureThe converter is configured according to the following steps:

1. Select type of configuration (single-motor drive, multi-motor drive, redundant or twin configuration).

2. Select field of application.

3. Indicate number of motors.

4. Select the appropriate inverter configuration for each motor based on the main data.



Chapter 9 - Ordering information ABB

5. Select the type of rectifier (ARU or LSU) based on process needs and braking capability requirements.

6. Add a RBU or BCU to an ACS 6000 with LSU if emergency braking capabilities are required.

7. Select options if needed. The available options are listed in Chapter 10 - Options.

9.2.3 Configuration rulesThe following power ratings for line rectifiers and motor inverters are available:

• ARU: 7, 9 and 9/11 MVA peak

• LSU: 5, 7, 9 and 14 MVA

• INU: 3, 5, 7, 9, 9/11 MVA peak and 11 MVA continuous power

Using the configuration rules for the ACS 6000, several rectifier and inverter units can be connected to the same common DC bus to supply big motors or more than one motor.

The following rules apply:

• Number of ARUs + INUs ≤ 7

• Total number of motors if supplied by ARU ≤ 4

• Total number of motors if supplied by LSU ≤ 5

• Number of ARUs ≤ 3

• Number of LSUs ≤ 4

• Combinations of ARU and LSU are not allowed

Note that these are only the most important rules. For a detailed list refer to the ACS 6000 Type code (3BHS128455 ZAB E01).

The alignment of the converter units within a line-up is predefined.

9.3 Type codeSee ACS 6000 Type code (3BHS128455 ZAB E01)

9.4 Option listSee Chapter 10 - Options.

9.5 External system dataSee Chapter 7 - Engineering information.


144

ABB Chapter 9 - Ordering information

9.6 Technical dataSee Appendix - Technical data.


Chapter 9 - Ordering information ABB


144

ABB

Chapter 10 - Options

10.1 Converter hardwareProcess I/Os • Standardized hardwired motor and transformer monitoring

For details, see Standard and Optional I/O Configuration (3BHS123187 ZAB E01).

• Customer specific hardwired I/Os

For details, see Standard and Optional I/O Configuration (3BHS123187 ZAB E01).

• Connection to process control

For details, see Chapter 6 - Control system and process interfaces, 6.4 Fieldbus interfaces.

AC disconnectors • Motor operated disconnector and grounding switches on the motor side:

• Grounding switch (1 in Figure 10-1)

• Disconnector (2 in Figure 10-1)

• Disconnector with grounding switch for motor (4 in Figure 10-1)

• Disconnector with grounding switch for converter (3 in Figure 10-1)

Figure 10-1 Output switch types

Cabinets • Cable entry from top (power and/or control cables)

(11 MVA cont. power, cable entry only from bottom)

1 2 43


Chapter 10 - Options ABB

• Water connection from top

• Cable transits (ROX - cable transits)

ROX cable transit frames are a standard feature.

• Higher IP rating (IP 44, IP 54)

• Non-standard cabinet color

• Language of warning labels

• Customer specific labels

Instrumentation • Insulation monitoring device for medium voltage circuit

• Pulse encoder interface (NTAC board) for rotor speed measurement

• Fast I/Os (NBIO-21)

Ambient conditions • Extended altitude range up to 4500 m above sea level (requires output power derating)

• Extended cooling water temperature range (10 °C...36 °C)

• Extended ambient temperature range (5 °C...45 °C)

• Heating cables (approx. 100 W/m)

Enhanced corrosionprotection

• Nickel-coated busbars

• Varnished circuit boards

10.2 Options for WCUThe following items can be ordered as options:

• Leakage sensor for WCUs which are closed to atmospheric pressure.

The sensor enables monitoring of the water cooling cabinet for leakage. The sensor is installed above the floor of the WCU. The reaction of the converter on a leakage (alarm message or shutdown) is adjustable with a parameter.

Figure 10-2 Leakage sensor

• Raw water valve (external to water cooling unit)


154

ABB Chapter 10 - Options

• Raw water filter (external to water cooling unit)

• Monitoring of external water temperature

The feature enables monitoring of the water temperature of the external cooling circuit. The voltage or current signal from a temper-ature monitoring device is connected to an anlog input module inside the WCU. When the signal increases above a parameter adjustable limit value, an alarm message is issued by the converter.

• Heat exchanger plates made of titanium

• Water cooling unit without heat exchanger for applications with fin fan cooler or chiller

• Deionized / distilled water for pure water circuit

• Glycol in deionized water (requires output power derating)

• Glycol in raw water (requires output power derating)

• High raw water pressure (10...16 bar)

• Flexible raw water connection

10.3 Converter software• Adjustable power factor

The software option enables the ARU to compensate reactive power generated by other loads connected to the same network. The MVA rating of the converter remains unchanged. This option requires further system calculations.

• Programming of customer specific I/O configuration

Applicable for options CIW3, CIU3 and CIUe according to Chapter 6 - Control system and process interfaces, 6.5.3 Interface configura-tions.

• Language of panel messages (standard language is English)

10.4 Service and diagnostics• Spare parts sets

• Minimum set for commissioning

• Medium set for 1...2 years of operation

• Maximum set for 3...5 years of operation.

• Tool sets for installation, commissioning and maintenance

• DriveWindow PC tool

Visualization software for:

• Displaying system configuration



• Monitoring actual signal values

• Viewing and changing parameters

• Fault logger

• Event logger

• Data logger for fast and accurate measurements

• Drive control

• Backup and restore

Communication between the ACS 6000 and the PC is achieved via fiber optic cables and PCMCIA card.

Figure 10-3 Typical DriveWindow display

• DriveMonitor

DriveMonitorTM is an option enabling real-time access to the diagnostic data of the ACS 6000. DriveMonitorTM allows monitoring of up to 9 drives and provides an Ethernet port to an external PC, to the Intranet of the customer or the Internet. The Internet connection enables ABB service engineers to monitor the performance of the drive without being on site.

The hardware consists mainly of a door-mounted optional touch-screen and a PC for data acquisition, storage and processing.

The standard solution is a stand-alone PC, not mounted in the converter cabinet. Optionally, the DriveMonitorTM can be installed in a console and equipped with a monitor as shown in Figure 10-4.


154


DriveMonitorTM provides the following functions:

• Acquisition of all available drive data thus ensuring that no data will be lost in the event of a drive failure

• Fault and alarm notification with causes and hints for rectification

• Automatic reporting on predefined templates

• Automatic recording of parameter changes

• Tracking of operational conditions

• Long-term data logging for monitoring of component lifetime

• Remote diagnostics according to the service and support-line contracts

See DriveMonitorTM User and Commissioning Manual for further details on DriveMonitorTM.

Figure 10-4 ACS 6000 with DriveMonitorTM installed in a console

DriveMonitorTM Embedded PC



• Drive OPC

A suite with SW modules for building customized PC applications with signal exchange between PC and drive system, e.g. production planning and statistics, preventive maintenance planning and others.

• DDCS branching unit for DriveWindow to access all AMC controllers from one location

• Service contracts

10.5 Optional customer interfacesThe optional customer interfaces are listed in Standard and Optional I/O Configuration (3BHS123187 ZAB E01).

10.5.1 I/O with option CIW1 (standard software)The option is available for single-motor drives and consists of five predefined S800 I/O modules which are connected to an AMC controller.

Refer to Standard and Optional I/O Configuration (3BHS123187 ZAB E01).

10.5.2 I/O with option CIW2 and CIW3 (project specific SW) The options CIW2 and CIW3 include the same number and type of S800 I/O modules as option CIW1 and additionally a programmable AC 80 / AC 800 controller. Unlike option CIW2, the software programming is included in option CIW3.

Furthermore, it is possible to replace the five I/O modules by other S800 modules and allocate the I/Os to specific functions depending on the user’s needs.

Refer to Standard and Optional I/O Configuration (3BHS123187 ZAB E01).

10.5.3 I/O with option CIUe The option CIUe is a project specific engineered I/O solution according to the type code. It includes the AC 80, AC 800M or AC 800PEC controller with S800 I/O modules according to project needs.

10.5.4 AC 80 / AC 800 controllerThe AC 80 / AC 800 controller is used with the options CIW2, CIW3 and CIUe and offering the possibility to program control, monitoring and protection functions for external equipment. When part of the ACS 6000 control system, the AC 80 / AC 800 is mounted on the control swing frame inside the WCU or inside the optional cabinet CIUe and is linked to the AMC controller of COU1.


154


Figure 10-5 S800 I/O configuration with AC 80 / AC 800

10.6 Marine versionThe marine versions of the ACS 6000 cabinets have the following additional features:

• Vibration Damping

The damping strip is attached between the mating surfaces of base frame and cabinet underside. The damping strip prevents ship vibra-tions being conveyed to the converter.

• Horizontal door handles

Figure 10-6 Marine version

TB 820 TB 820 AC 80 / AC 800

AMC controller

DDCS

CH 7

S80

0 M

odul

e B

us

S80

0 M

odul

e B

us

S80

0 M

odul

e B

usDI 810

DO 810

DI 810

DO 820

DI 810

DO 820

AI 820

AI 820

DI 810

AO 820

DO 820

AI 820

CH 4DDCS

Controller

WCUCOU1 CIW2 / CIW3

Damping mat between base frame and converter cabinets

Marine-type door handles



• Door arresters

All doors are equipped with door arresters. When a door is opened, the door arrester engages and holds the door in the open position.

Figure 10-7 Door arrester

• Roof fixings

ACS 6000 converters for marine applications are supplied with roof attachments for fastening the converter to the ceiling or the back wall of the drive room. The roof attachments prevent tilting of the converter (see Figure 10-8) and serve as vibration dampers. The number of roof attachments per drive depends on the length of the line-up. The roof attachments are assembled on site.

Figure 10-8 Roof fixings

45°45°

90°

Assembled roof attachment Ceiling fastening Wall fastening

Roof-sidesteel bracket

Wall-sidesteel bracket

Rubber pad

Sleeve


154


Figure 10-9 Roof connecting pieces

• Heating cables

• Extended range for cooling water and ambient temperature

• Varnished circuit boards

• Leakage sensor in WCU

10.7 Transportation, installation and commissioning• Sea freight packing (Incoterm EXP)

• Make-up water

• Erection

• Commissioning

10.8 Training• Operation and maintenance training

Training on operation, maintenance and troubleshooting (including replacement of circuit boards, phase modules and semiconductors) of the ACS 6000 converter.

• Commissioning and maintenance training

Same as above but extended by commissioning.

10.9 Testing• Additional non-standard tests

• Customer witness test

• Additional external tests

• Production supervision

Connecting pieces at thefront and at the back



10.10 Documentation• Paper copies of the user’s manual (user’s manual on CD-ROM is

standard)


154

ABB

Index

AActive Rectifier Unit ARU 74Application Control 42

Bbasic configuration 23Bus Bars 64

CCabinet Design 62Control Features (DTC) 41Control System 103Crowbar Thyristors 72, 74

Ddi/dt choke 72, 74Direct Torque control, methods 39drilling rig 27

FFour-quadrant operation 20

GGrounding 64

IInverter Unit INU 78

LLine Supply Unit 70Load Share Control 42

MMain Circuit Breaker 42Main circuit breaker, selection 125Main State Machine 124

mine hoist 35Motor Control Functions 41Motor Requirements 126Multi machine drive 25multiple units 25

OOperating System 123Oscillation Damping 41overland conveyors 36

Ppower range 15Protection Functions 49

RRolling Mill Applications 30Rougher mill 32

Ssendzimir mill 34single machine configuration 17Single machine drives 24Speed Control 41

TTorque Control 41

VVoltage Limiting Unit 97, 99, 101


ABB


157

ABBABB Switzerland LtdMedium Voltage DrivesCH-5300 Turgi / SwitzerlandTel +41 58 589 27 95Fax +41 58 589 29 84Email [email protected]

www.abb.com/motors&drives

ABB Switzerland Ltd reserves all rights to this document. Unauthorised duplication is not permitted.

3BHS123322 ZAB E01 Rev. D18-09-2009

ABB

Appendix A -Technical data

Converter output / Motor connection

"x" stands for S (single-motor drive), M (multi-motor drive), R (redundant drive) and T (twin drive)"..." stands for several digits of the type code (see Appendix C - ACS 6000 Type Code)"y" stands for asynchronous motors, synchronous motors and synchronous motors with brushless

excitation

Output frequencyrange

0...75 Hz

Minimal basefrequency

3.1 Hz

Maximum fieldweakening range

1:5

Maximum motor cablelength

300 m (984 ft), longer on request

Efficiency Depends on individual configuration

Static speedinaccuracy

With encoder: within +/- 0.01%

Without encoder: within +/- 0.1%

Dynamic speedinaccuracy

With encoder: within 0.2 ... 0.5% s

Without encoder: within 0.5 ... 1% s

Air gap torque ripplecomponents

< 1% (Motor fn <25 Hz, frequency components below 100 Hz)



Power factor forsynchronous motors

Controlled to 1.0

Power factor forasynchronous motors

Depends on motor characteristics

Table A-1 Output voltage and current ratings

Type Rated output voltage with ARU

Rated output voltage with LSU with 2 x 1725 V input

voltage

Rated output voltage with LSU with 2 x 1650 V

input voltage

Rated output current

ACx ... _1y7 3150 ... 3300 V 3000 ... 3100 V 3000 V 1300 A

ACx ... _1y9 3150 ... 3300 V 3000 ... 3100 V 3000 V 1670 A

ACx ... _2y7 2 x 3150 ... 3300 V 2 x 3000 ... 3100 V 2 x 3000 V 2 x 1300 A

ACx ... _2y9 2 x 3150 ... 3300 V 2 x 3000 ... 3100 V 2 x 3000 V 2 x 1670 A


Appendix A - Technical data ABB

ACS 6000 with Active Rectifier Unit (ARU)

"x" stands for S (single-motor drive), M (multi-motor drive), R (redundant drive) and T (twin drive)"..." stands for several digits of the type code (see type code sheet)"y" stands for asynchronous motors, synchronous motors and synchronous motors with brushless

excitation

Input voltage variations Safe operation with reduced output power is possible down to -20% for 3160 V input voltage.

Phase shift Phase shift between transformer secondary windings:

• 30° for 12-pulse ARUs

• 20° for 18-pulse ARUs

Input frequencies 50 / 60 Hz ± 5%

Voltage unbalance max. ± 2% (Uneg / Upos according to IEC 61000-2-4)

Fundamental powerfactor cos ϕ

Controlled to cos ϕ = 1.0

Optionally, cos ϕ can be controlled in a range of 0.8 (leading) ... 0.8 (lagging).

(MVA ratings remain the same as for cos ϕ = 1.0)

Maximum cable length 300 m (984 ft)

Control principle Vector control with optimized pulse patterns

Table A-2 Input voltage and current ratings

Type Input voltage Rated input current Pulses EMC filter (IFU)

ACx 6107_A06_... 1 x 3160 V, +10/-10% 1 x 1300 A 6-pulse No

1 x 3000 V, +15/-5% 1 x 1300 A 6-pulse No


1 x 3000 V, +15/-5% 1 x 1670 A 6-pulse No

ACx 6109_F06_... 1 x 3160 V, +10/-10% 1 x 1300 A 6-pulse Yes

1 x 3000 V, +15/-5% 1 x 1300 A 6-pulse Yes


2 x 3000 V, +15/-5% 2 x 1380 A 12-pulse No


2 x 3000 V, +15/-5% 2 x 1670 A 12-pulse No


3 x 3000 V, +15/-5% 3 x 1670 A 18-pulse No


ABB Appendix A - Technical data

ACS 6000 with Line Supply Unit (LSU)

"x" stands for S (single-motor drive), M (multi-motor drive), R (redundant drive) and T (twin drive)"..." stands for several digits of the type code (see type code sheet)"y" stands for asynchronous motors, synchronous motors and synchronous motors with brushless

excitation

Phase shift Phase shift between transformer secondary windings:

• 30° for 12-pulse LSUs

• 15° for 24-pulse LSUs

Input frequencies 50 / 60 Hz ± 2%

Voltage unbalance max. ± 2% (Uneg / Upos according to IEC 61000-2-4)

Fundamental powerfactor

cos ϕ > 0.95

Maximum cable length 300 m (984 ft)

Table A-3 Input voltage and current ratings

Type Input voltage Rated input current pulses

ACx 6107_D06_... 1 x 3300 VAC, +10/-10% 1 x 1300 A 6-pulse

ACx 6107_L12_... 1 x 2 x 1725 VAC, +10/-10% 1 x 2 x 1300 A 12-pulse

1 x 2 x 1650 VAC, +15/-5% 1 x 2 x 1300 A 12-pulse


1 x 2 x 1650 VAC, +15/-5% 1 x 2 x 1670 A 12-pulse


1 x 2 x 1650 VAC, +15/-5% 1 x 2 x 2600 A 12-pulse


2 x 2 x 1650 VAC, +15/-5% 2 x 2 x 1300 A 24-pulse


2 x 2 x 1650 VAC, +15/-5% 2 x 2 x 1670 A 24-pulse


2 x 2 x 1650 VAC, +15/-5% 2 x 2 x 2600 A 24-pulse



Auxiliary supply

Auxiliary voltage • 380 VAC +/-10%, 3-phase

• 400 VAC +/-10%, 3-phase

• 415 VAC +/-10%, 3-phase

• 440 VAC +/-10%, 3-phase

• 460 VAC +/-10%, 3-phase

• 480 VAC +/-10%, 3-phase

• 500 VAC +/-10%, 3-phase

• 660 VAC +/-10%, 3-phase

• 690 VAC +/-10%, 3-phase

Auxiliary voltagefrequency

50 / 60 Hz, +/-2%

Uninterruptible powersupply

110 VDC

220 VDC

110 VAC, 1-phase

230 VAC, 1-phase

EXU supply

Auxiliary voltage • 380 VAC +/-10%, 3-phase

• 400 VAC +/-10%, 3-phase

• 415 VAC +/-10%, 3-phase

• 440 VAC +/-10%, 3-phase

• 460 VAC +/-10%, 3-phase

• 480 VAC +/-10%, 3-phase

• 500 VAC +/-10%, 3-phase

• 660 VAC +/-10%, 3-phase

• 690 VAC +/-10%, 3-phase

Auxiliary voltagefrequency

50 / 60 Hz, +/-2%



Storage, Transportation and Operation

Storage

Storage conditions The storage conditions are based on IEC 60721-3-1 'Classification of groups of environmental parameters and their severities; Storage'.

1 Requirement of classification societies: American Bureau of Shipping,Bureau Veritas, Det Norske Veritas, Germanischer Lloyd, Lloyd’sregister

Storage time Up to one year in the original packaging

Transportation

Transportationconditions

The transportation conditions are based on IEC 60721-3-2 'Classification of groups of environmental parameters and their severities; Transportation'

Parameter Limits

1K4 Climatic conditions

Air temperature -25... +55 °C (-13 °F... 131°F)

Relative humidity 5...100 %

Absolute humidity 0.5...29 %

1Z3 Special Climatic Conditions

Movement of surround. air 30 m/s (98 ft/s)

1B1 Biological conditions

Flora negligible

Fauna negligible

1M 3 Mechanical conditions

Vibration:

• displacement amplitude 3 mm ( 0.12 in.) - (2...9 Hz)Marine application1:1 mm (0.04 in.) - (5...13.2 Hz)

• acceleration amplitude 10 m/s2 - (9...200 Hz)Marine application1: 7 m/s2 (23 ft/s2) - (13.2...100 Hz)



.

1 Requirement of classification societies: American Bureau of Shipping,Bureau Veritas, Det Norske Veritas, Germanischer Lloyd, Lloyd’sregister

2 An angle of 35° (pitching) can only occur temporarily, angles up to 22.5°(rolling) can occur for long periods of time.

Parameter Limits


Low air temperature -40 °C (-40 °F)

High air temperature:

• unventilated enclosures 70 °C (158 °F)

• ventilated enclosures/outdoor 40 °C (104 °F)

Relative humidity 95 %

Absolute humidity 60 %


Flora no

Fauna no

2M1 Mechanical conditions

Stationary vibration sinosoidal:

• displacement amplitude 3.5 mm (0.14 in) - (2...9 Hz)

• acceleration amplitude 10 m/s2 (33 ft/s2) - (9...200 Hz)

15 m/s2 (49 ft/s2) - (200...500 Hz)Marine application1:15 m/s2 (49 ft/s2) - (9...200 Hz)

Stationary vibration random:

• acceleration spectral density 1m2/s3 (3.3 ft2/s3) - (10...200 Hz)

0.3 m2/s3 (0.98 ft2/s3) - (200...2000 Hz)

Non-stationary vibration (incl. shock):

• shock response spectrum 100 m/s2 (328 ft/s2)

Free fall 0.1 m (0.33 ft) - (mass > 100 kg [220 lb])

Toppling no (mass > 100 kg [220 lb])

Rolling, pitching2:

• degree no

• period no

Steady-state acceleration 20 m/s2 (66 ft/s2)



Max. transport time Two months

Operation

Operation conditions Operation conditions are according to IEC 721-3-3 ’Stationary use at weather-protected locations’.

Parameter Limits


Air temperature* 5...40 °C (41...104 °F)Marine application:5...45 °C (41...113 °F)Temperature may drop temporarily below 0 °C (32 °F)

Relative humidity 5...85 %

Absolute humidity 1...25 g/m3 (0.036 lb/in3)

Condensation no


Flora no

Fauna no

3C2 Chemically active substances

Sea salt and road salts Salt mist

Sulphur dioxide 0.3...1.0 mg/m3

(1.084x10-11... 3.613 x10-11lb/in3)

Hydrogen sulphide 0.1...0.5 mg/m3

(3.613x10-12... 1.806x10-11lb/in3)

Chlorine 0.1...0.3 mg/m3

(3.613x10-12... 1.0838x10-11lb/in3)

Hydrogen chloride 0.1...0.5 mg/m3

(3.613x10-12... 1.806x10-11lb/in3)

Hydrogen fluoride 0.01...0.03 mg/m3

(3.613x10-13...1.0834x10-12lb/in3)

Ammonia 1...3 mg/m3

(3.613x10-11...1.084x10-10)

Ozone 0.05...0.1 mg/m3

(1.806x10-12...3.613x10-12)

Nitrogen oxides 0.5...1.0 mg/m3

(1.806x10-1...3.613 x10-11lb/in3)

3S2 Mechanically active substances

Sand 30 mg/m3 (1.084x10-9)

Dust (suspension) 0.2 mg/m3 (7.225x10-12)



* Lower temperatures are permitted, as long as it is guaranteed that thecooling water cannot freeze (to be specified by ABB for each drive).

** Requirement of classification societies: American Bureau of Shipping,Bureau Veritas, Det Norske Veritas, Germanischer Lloyd, Lloyd’sregister

Rotation around X-axes (Rolling)

Up to 22.5°

Installation altitude • 0...2000 m (6562 ft) - with rated drive power

• Above 2000 m (6562 ft) to 5000 m (16404 ft) - with reduced drive power (please contact ABB)

Sound pressure level < 75 dB (A)

FrostproofingLowest permitted freezing point: -25°C (-13°F)

Permitted anti-freeze: pure monoethylene glycol

Water glycol concentration for the desired frostproofing:

Dust (sedimentation) 1.5 mg/m3 (5.419x10-11)

3M3 Mecanical conditions

Stationary vibration sinosoidal:

• displacement amplitude 1.5 mm (0.06 in) - (2...9 Hz)Marine application:1.0 mm (0.04 in) - (5...13.2 Hz)

• acceleration amplitude 5 m/s2 (16.4 ft/s2) - (9...200 Hz)Marine application**:7 m/s2 (23 ft/s2) - (13.2...100 Hz)

Non-stationary vibration (incl. shock):

• shock response spectrum 40 m/s2 (131.2 ft/s2)

Parameter Limits

0

-10

-20

-30

-40

-50

-600 20 40 60 80 100

°C

% volume10 30 50 70 90

Frost proofing Glycol Distilled Water

- 10 °C (14 °F) 20 % 80 %

- 20 °C (-4 °F) 34 % 66 %

- 30 °C (-22 °F) 44 % 56 %

- 40 °C (-40 °F) 52 % 48 %



Cooling

Cooling method Water-cooled closed loop system

Raw water quality Raw water of good quality is essentially “industrial water”and must meet the following requirements:

Raw water connectionrequirements

* Nominal values; values vary depending on application** Lower temperatures are permitted, as long as it is guaranteed that the

cooling water cannot freeze.

Raw water connection The raw water pipes are connected to the Water Cooling Unit (WCU) with two flanges which are part of the supply. Pipe entry is through the top or the bottom of the WCU cabinet.

Parameter Value

pH 7 – 9

Specific conductivity < 500 μS/cm

Hardness 3 – 15° dH

Chloride (Cl) < 300 mg/l

Total dissolved salt < 1000 mg/l

Undissolved particles < 1000 mg/l

Total M-alkalinity (TAC) 0 – 300 mg CaCO3/l

Raw water connection Remarks

Flow rate 250 - 870 l/min* Depending on required cooling capacity

Pressure drop 70 - 160 KPa* (0.7 -1.6 bar)* Depending on drive size and application

Design pressure 1000 KPa* (10 bar)*

Test Pressure 1500 KPa* (15 bar)*

Raw water pressure 20 - 50 KPa (0.2 - 0.5 bar) Optional: up to 100 kPa (1 bar)

Inlet temperature** 5 - 32 °C* (41 - 90 °F) Operation with rated power

5 - 36 °C* (41 - 97 °F) Marine applications

Extended temperature 32 - 42 °C* (90 - 108 °F) Output current is derated by 1.5%/degree

Outlet temperature** 5 - 37 °C* (41 - 99 °F)

5 - 42 °C* (41 - 108 °F) Marine applications



Internal cooling circuit The internal main cooling circuit of the converter is operated with de-ionized water as specified below:

Drinking water of good quality generally meets the requirements for make-up water and may be used. Conditioning the make-up water will result in an initial reduction of the deionizer resin capacity by about 10%.

The required quantity of deionized water depends on the configuration of the drive (e.g. number of INUs, EXU). The required quantity is specified on the mechanical drawings supplied with the converter.

Heat dissipation toenvironment

Approx. 6% of the losses

Converter enclosure

Standard enclosureclass

IP32

Cabinet color RAL 7035 "light gray"

Filter meshDoor filter mats in converters with IP 54 are specified for filter particles with a size > 10 μm.

Overview of derating factors for converter output power

Raw water temperature If the raw water temperature exceeds 32 °C (90 °F), the output current will be derated by 1.5%/°K. The maximum raw water temperature is 42 °C (108 °F).

Antifreeze Antifreeze (monoethylene glycol) in the internal water circuit requires output power derating.

Antifreeze in raw water requires output power derating.

Low speed operation Continuous current derated to 70% / 0 Hz ... 70% / 3 Hz ... 100% / 8 Hz

Parameter Value

pH 7 – 8.5

Specific conductivity < 300 μS/cm

Hardness 3 – 10° dH

Chloride (Cl) < 300 mg/l

Copper (Cu) < 0.1 mg/l

Total dissolved salt < 1000 mg/l

Undissolved particles < 5 mg/l



Input filter unit If an IFU is used, the continuous power of the ARU is derated to max. 7 MVA.

Converter test voltages

Test voltages

Impulse test voltage[kVpeak]

30 kV according to IEC / EN 60071-1

Dielectric withstandvoltage

10 kV

Electromagneticcompatibility

According to IEC / EN 61000-4-2:

• Contact discharge: 6 kV

• Air discharge: 8 kV


• Aux-supply power-ports: 2 kV, 5 kHz

• Signal-ports: 1 kV, 5 kHz


• Aux-supply power-ports line-to-earth: 2 kV

• Aux-supply power-ports line-to-line: 1 kV

• Signal-ports: 1 kV




ABB

ACS 6000 - Applicable Codes and Standards.

International Standards for Design and Construction

IEC / EN 60071-1 Insulation coordination - Part 1: Definitions, principles and rules

IEC / EN 60146-1-1 Semiconductor convertors - General requirements and line commutated convertors - Part 1-1: Specifications of basic requirements

IEC / EN 60529 Degrees for protection provided by enclosures (IP-Code)

IEC / EN 60664-1 Insulation coordination for equipment within low-voltage systems - Part 1: Principles, requirements and tests

IEC 62103 (EN 50178) Electronic equipment for use in power installations

IEC / EN 61800-4 Adjustable speed electrical power drive systems - Part 4: General require-ments - Rating specifications for a.c. power drive systems above 1000 V a.c. and not exceeding 35 kV

EMC Standards

CISPR 11 Industrial, scientific and medical (ISM) radio-frequency equipment - Elec-tromagnetic disturbance characteristics - Limits and methods of measure-ment

IEC / EN 61000-4-2 Electromagnetic compatibility (EMC) - Part 4-2: Testing and measurement techniques - Electrostatic discharge immunity test

IEC / EN 61000-4-3 Electromagnetic compatibility (EMC) - Part 4-3: Testing and measurement techniques - Radiated, radio-frequency, electromagnetic field immunity test

IEC / EN 61000-4-4 Electromagnetic compatibility (EMC) - Part 4-4: Testing and measurement techniques - Electrical fast transient/burst immunity test

IEC / EN 61000-4-5 Electromagnetic compatibility (EMC) - Part 4-5: Testing and measurement techniques - Surge immunity test

IEC / EN 61000-4-6 Electromagnetic compatibility (EMC) - Part 4-6: Testing and measurement techniques - Immunity to conducted disturbances, induced by radio-frequency fields

IEC / EN 61000-6-2 Electromagnetic compatibility (EMC) - Part 6-2: Generic standards - Immunity for industrial environments

IEC / EN 61000-6-4 Electromagnetic compatibility (EMC) - Part 6-4: Generic standards - Emis-sion standard for industrial environments

3BHS125313 ZAB E01 Rev. B 1 (2)

ABB

IEC / EN 61800-3 Adjustable speed electrical power drive systems - Part 3: EMC require-ments and specific test methods

Environmental Standards

IEC / EN 60721-3-1 Classification of environmental conditions – Part 3: Classification of groups of environmental parameters and their severities – Section 1: Storage

IEC / EN 60721-3-2 Classification of environmental conditions – Part 3: Classification of groups of environmental parameters and their severities – Section 2: Transport

IEC / EN 60721-3-3 Classification of environmental conditions – Part 3: Classification of groups of environmental parameters and their severities – Section 3: Stationary use at weatherprotected locations

Standards Marine and Offshore Applications

IEC / EN 60092 Electrical installations in ships

Marine Classification Societies

The ACS 6000 meets the requirements of the following classification societies:

• American Bureau of Shipping (ABS)

• Bureau Veritas (BV)

• Det Norske Veritas (DNV)

• Germanischer Lloyd (GL)

• Lloyd’s Register (LR)

2 (2) 3BHS125313 ZAB E01 Rev. B

ABB ACS 6000 Tech Catalog RevD

Documents

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det norske veritas

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capacitor bank unit

short circuit detection

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