ACS2000.pdf

ABB Group March 16, 2010 | Slide 1

IEEE-ICIT 2010 CHILE A New Medium Voltage Drive System Based on ANPC-5L Technology

Michael Basler, ABB Switzerland Ltd, March 2010


Overview

A new medium voltage drive system

The ANPC-5L topology

Converter configurations

System integration

Converter design


New Medium Voltage Drive System Overview

ACS 2000 launched by ABB in 2010

General purpose drive for standardapplications

Voltage source inverter

Medium voltage 66.9kV

Low power (400 kVA 1000 kVA)

Compact size

Multilevel IGBT topology

Air cooled

Suitable for standard motors and input isolation transformers


New Medium Voltage Drive System Overview

Suitable for use with or without input isolation transformer

Direct-to-line connection (transformerless) provides lowest cost of ownership

Active Front End (AFE) for minimal line side harmonics with power factor correction and regeneration

Simple drive system integration

Three in - three out cabling for quick and easy installation

Suitable for new or existing induction motors

High reliability and low maintenance costs


The ANPC-5L Topology General topology facts

ACS 2000 is based on a new 5-level VSI topology Different from existing 5-level topologies (ACS 5000)

Main reason: requirement for transformer-less operation

ACS 2000 topology combines two innovations for ABB MV-drives New innovative 5-level VSI topology (from ABB CRC)

Dual switch HV IGBT technology

ACS 2000 is exclusively available with an Active Front End (AFE) to support either transformerless design or

simple 2-winding transformer design


The ANPC-5L Topology General topology facts

5-level topology chosen in ACS 2000 is an extension of the well-established 3-level VSI

Main differences to 3-level VSI topology include Additional capacitor per phase phase capacitor NP diodes are extended by antiparallel active switches Active Neutral Point Clamped (ANPC)

Phase capacitor is charged to of the total DC-link voltage To provide an additional level in the output voltages

To have equally spaced steps in the output voltage


The ANPC-5L Topology From 3-level to 5-level topology

3-Level NPC VSI (ACS 1000 or ACS 6000)

+VDC

NP

-VDC

PH



3-Level NPC VSI

Phase output voltages

+VDC

NP

-VDC

VPH



3-Level NPC VSI


+VDC

NP

-VDC

VPH



From 3 levels to 5 levels:

+VDC

NP

-VDC

PH




+VDC

NP

-VDC

PH

1. Replacing IGCTs with IGBTs




Vdc/2

+VDC

NP

-VDC

PH

1. Replacing IGCTs with IGBTs2. Adding the Phase Capacitor

Charged to of the total DC-link voltage


The ANPC-5L Topology Phase to ground voltage levels

5-Level ANPC VSI


+VDC

NP

-VDC

+VDC/2

-VDC/2

VPH



5-Level ANPC VSI


+VDC

NP

-VDC

+VDC/2

-VDC/2

VPH


The ANPC-5L Topology Phase to phase voltage levels



The switching vectors are symmetrical for the negative side of the waveform.



0 0.005 0.01 0.015 0.02 0.025 0.03 0.035 0.04-15

-10

-5

0

5

10

15

v ol t a

g e ( k

V)

Converter phase to phase voltage

time(s)


The ANPC-5L Topology Controlling the phase capacitor voltage

Vdc/2

+VDC

NP

-VDC

PH

Some vectors produce the same output voltage V5 and V6 produce +VCD/2

V1 and V2 produce -VCD/2

Redundant vectors are used to control the voltage level of the phase capacitor

Current direction changes in phase capacitorV5

V6


The ANPC-5L Topology Network side

Active Front End (AFE) with Input Filter Unit (IFU), di/dt clamp and DC-link capacitors

+++

+

+


The ANPC-5L Topology Motor side

Inverter unit (INU) with di/dt clamp and output filter for du/dtlimitation


The ANPC-5L Topology Protection against short-circuit

Two Lines of Defense

Fast short-circuit protection on semiconductor level

If a gate-emitter voltage is applied during on-state (saturation of IGBT) a short circuit is detected and turned off.

Protection firing on system level

Thyristor crowbar located in the DC link is operated to discharge the DC link and phase capacitors. Subsequently protection firing (turning on all IGBTs) is initiated.

Eliminates the possibility of IGBT explosion


Converter Configurations Connection to external transformer


Converter Configurations Direct-to-line connection


Converter Configurations Direct-to-line connection

Control UnitControl

UPS Power Supply

Auxiliary Power Supply

MCB (Standard)CloseOpenTrip

Main Power Supply

Motor

IM

Auxiliaries

Power Part

ACS 2000


System Integration Requirements

Trends in the industry:

From an engineered solution to a more standardized solution.

From a one of a kind solution to a commodity.

Standard drive interfaces

Motor side no special motor required

Line side meet common network standards

only simple input breaker needed

Controls HW level flexible I/Os

SW level common ABB profile Cooling Simple integration possible


System Integration Drive system configurationsMain power supply

M

Main circuit breaker

Transformer

ACS 2000

Motor

Classic configuration with

external transformer

M

Direct-to-line (DTL)

connection

M MM

Several direct-to-line drives on a common AC bus


Converter Design ACS 2000 converter

Cooling fan

Control unit

Inverter Phase Modules

Active front end (AFE) Phase Modules

Cable entry


Converter Design Cabinet front

Phase modules

Control unit

DC-link

Terminal field

Input filter choke


Converter Design Cabinet back

Output filter choke

DC busbar with di/dt clamp

Filter resistors

Input filter choke


Converter Design Phase module

Connectors

Phase interface

control board

Phase

capacitor


Converter Design Phase module

Phase capacitor

Low inductive busbar

IGBT modules

Gate units

Heatsink

Integrated current sensor


Converter design Main features

Compact size

Ease of service

Redundant cooling

Front access to all components

Phase module exchange in less than 30 minutes

Modular design


A New Medium Voltage Drive System Based on ANPC-5L Technology Conclusion

ACS 2000 was successfully launched on the market

Introduction in waves to ensure smooth market introduction

Stages Countries Internal launch1st wave UK, SE, ES, IT, CZ, PL Q2, 2009 2nd wave Rest of Europe Q3, 2009 3rd wave NAS & SAS Q1, 2010 4th wave SAM, NAM & MEA Q2, 2010

Successful collaboration between research and industry

Second presentation on ACS 2000

PE-3: Power Electronics Part 3

Tuesday 16, 11:50-12:10

A New Medium Voltage Drive System Based on ANPC-5L Technology (VF-009288),

Frederick Kieferndorf

Documents

ACS2000.pdf