Extension Cord Safety Module 2

Kai Mossig ACS 1000
Product Manager
ACS 1000 Product Overview
© ABB Switzerland Ltd. MV Drives
Objectives of Presentation
 Overview
 Voltage, Power Range and Main Versions
 Main Features
 Options
 Sinusoidal output  Drive Product with a wide
variety of Standard Options
 Efficiency >98%
 Less than 2 days com-
 IGCT technology
missioning for the drive
 Direct Torque
Control
 Square Torque or Constant Torque applications, e.g.:

 Pumps, fans, compressors, conveyors, extruders, mixers etc.
 1 or 2 Quadrant operation
 for induction motor control
ACS 1000 Product Portfolio
 Available Output Voltage and Power Range
(6’000 kVA)
5,000
Motor Power in kW
W3 Water-
W2 cooled
re-connection with
W1
2’000 A3 Air- cooled
of Motor
winding from
step- up
transformer
Star to Delta
A2
315 A1
6.0 6.9 8.0 13.8

2.3 3.3 4.0
Motor Voltage in kV
ACS 1000 Three- level Voltage Source Inverter (VSI)
ACS 1000 MV Variable Frequency Drive

Main Feeder Rectifier DC-Link & Inverter Output Sine
MV Converter Input Prot IGCTs Filter
Breaker
Supply Transformer
& Protection
I>> Prot
MV AC
Induction
Motor
Supply Side DC Link and Inverter Sine Wave

Protection IGCTs Output Filter
 Main Circuit Breaker, 12 pulse Transformer and Diode Rectifier stage

 Fuseless Design, using Protection IGCTs

 DC Link, DC Capacitors and Common Mode Choke (Option)
 Three-level Voltage Source Inverter (VSI) equipped with IGCTs
 Output sine wave filter
 ACS 1000i: Air cooled drive with integrated transformer
Air Cooled Drives
315 - 2000kW Applications

ACS1000 Air Cooled Front View
Air Cooled Range:
0.4 – 2.7 MVA;
2.3, 3.3 and 4kV;
2000 mm
excl.
air outlet
cover
3000 mm
900 mm
ACS 1000 Air Cooled Looking Inside ...
Cooling Fan Inverter

Control Rectifier DC Link and

Sine Filter Choke Sine Filter
Cap’s
ACS 1000 Air Cooled Air Flow
Noise Level: <75 dB (A)

with integrated fan
Air cooling circuit specification type of ACS 1000

-A1 -A2/-A3
max. heat transfer to the ambient 1.8 % of rated 1.8 % of rated
apparent drive apparent drive
power power
nominal cooling air flow 1.7 m3/sec 2.5m3/sec

ambient temperature min. 4 °C min. 4 °C
max. 40 °C max. 40 °C
(up to 50°C (up to 50°C
with derating) with derating)
Water Cooled Drives
2000 - 5000kW Applications

ACS1000 Water Cooled Front View
4200 mm for W1 frame size

4700 mm for W2 and W3 frame size
2000 mm
Water Cooled Range:

900 mm
2.7 - 6 MVA;
3.3 and 4kV;
ACS 1000 Water Cooled Looking Inside ...
Rectifier and Inverter
Sine filter
Capacitor
Cooling
Unit
DC Capacitors
Sine Filter
Choke Common
Control
mode
Choke
ACS 1000 Water Cooled Swing Frame for easy Maintenance
ACS 1000 Water Cooled Cooling Circuit Overview
Air cooled drive with
integrated Transformer
ACS 1000i
315 – 2000kW Applications

ACS 1000i - Overview
up to 2000kW / 2700hp
4.16kV
60Hz
2150 mm excl.
air outlet cover
2660 mm incl.
air outlet cover
Note: provide
min. 800mm
clearance for
free air flow !
3300 mm
1120 mm
Contactor Control
Line
connection Inverter
Motor
connection
Rectifier Transformer Sine filter
capacitor
 Maximum re-use of ACS 1000 components
 Extension of the existing ACS 1000 product family
ACS1000i specific All components identical with

components ACS1000
Medium Voltage Input Input 24-Pulse DC-Link Inverter Output Sine
Supply Bus Isolator and Transformer Rectifier Filter
Contactor
MV AC
Induction
Motor
ACS 1000i – Topology and Main Data
Contactor
MV AC
Induction
Motor
Line Isolator 5-winding 24-pulse DC-Link Inverter Output Motor

Supply and Trans- Rectifier Sine
Contactor former Filter
 Self-commutated 3-level VSI-NPC

 voltage source inverter, neutral point clamped
 using IGCT (integrated gate commutated thyristor) technology
 24-pulse diode supply
 fuseless converter design
 integrated transformer and input contactor
ASC 1000i – Line Side
Contactor
MV AC
Induction
Motor
Main Feeder
Breaker
 Typically supply from a feeder of customer’s MV

switchgear (but no requirement !)
 ACS1000i is (optionally) equipped with an integrated
input contactor
 no need for any control wiring between drive and

switchgear.
ACS 1000i – Line Side
 Mains Supply Data
 Supply voltage 6.0 .. 6.6 kV / 50 Hz
10 .. 11kV / 50Hz
4.16 / 60 Hz
other voltages up to
11 kV on request
 Supply voltage tolerance + 10 / - 5%

 Safe operation down to 75% supply voltage,
(while aux. power supply still +/- 10%!) with reduced power
 Maximum supply phase unbalance 2%
 Supply frequency 50 / 60 Hz
 Supply frequency tolerance ± 5%

 Total input power factor > 0.96
for 20 ... 100% load
ACS 1000i – Input Transformer
Contactor
MV AC
Induction
Motor
Main Feeder
Breaker
 5-winding transformer for 24-pulse harmonic line performance

 vacuum impregnated dry type transformer
 copper or aluminum windings
 class H insulation (180°C)
 temperature rise < 115 K for class H
 efficiency of 98 ... 98.5%

 Optional: 6th LV winding for cooling fan supply
 for 60Hz version only !
ACS 1000i – Input Transformer
 Built-in input surge protection
 “Heavy duty distribution class” Surge
arresters, installed at the isolation
transformer primary side
ABB type POLIM-D

ACS 1000i standard feature !

ACS 1000i – 24-pulse Rectifier
Contactor
MV AC
Induction
Motor
Main Feeder
Breaker
 24-pulse diode located in front

rectifier of the input
transformer
 diode modules
 very cost efficient
solution
 different from
ACS1000
ACS 1000i – Cooling
transformer
 Two independent cooling circuits cooling fan
inverter
 Transformer cooling fan
 Inverter
 Two top mounted cooling fans
 Ductable air outlet
 Standard supervision of:

 P in both circuits
 P across air filter
 Inverter temperature
 Transformer temperature
(one for middle winding)

ACS 1000, ACS 1000i
Main Features
Supply side
Medium Voltage Medium Voltage
Supply Bus Supply Bus
Main Feeder Main Feeder
I>> Prot I>> Prot
Breaker Breaker
& Protection & Protection
12-pulse 24-pulse
Converter Input Converter Input
Transformer Transformer
Rectifier
Rectifier
• Standard: 12 pulse- transformer and diode bridge

• Option: 24 pulse- transformer and diode bridge
• Converter transformer type: Oil- or dry type
 Conformity to IEEE 519/1992
 Total power factor: 0.95 constant over speed range

 Transformer can be placed inside the building or
outdoor
Supply side
 Supply Voltage Variation

 +/- 10%,
 down to –25% possible
 current limiter may reduce power
 Aux. power supply must remain within its limits (+/- 10%)
 max. 2% unsymmetry
 Aux. Supply (3-Phase)

 400 V / 50 and 60 Hz,
 480 V and 575 V / 60 Hz
 +/- 10%
Ride through capabilities
 Main power loss ride through  Auxiliary power loss ride

through

Main Feeder 12-Pulse DC-Link & Inverter Output Sine
MV Converter Input Rectifier Prot IGCTs Filter
Breaker
Supply Transformer
& Protection
I>> Prot
MV AC
Induction
Motor
Auxiliaries, Control, protection & supervision
Aux. Power Control Gate unit Cooling Add.

supply boards supply options
Main power loss ride through
• Fast response to mains UDC

interruptions UMIN
• Controlled operation during

fOUT
power loss
TM
• Default 5 sec ride-through
capability (parameter
adjustable, depends on 0 5 10 15 20 25
load inertia) Time (sec.)
UDC = DC voltage
UMIN = DC voltage minimum limit
fOUT = output frequency

TM = motor torque
Aux. power loss ride through
 Trigger of function:
 Loss of 3 phase supply, or
 Reduction of voltage of 3 phase supply by 20% to 25% percent (depending on the capabilities
of the aux. power supply modules from Phoenix)
 Functionality
 Internal batteries or 1 phase supply (safeline) will keep control fully operational
 Cooling will stop (fan and pump)  can be tolerated for short time
 Power has to return within specifc ride through time (otherwise “aux. power loss”-trip):
 ACS 1000 Air cooled 5 sec
 ACS 1000 integrated 5 sec
 ACS 1000 Water cooled 1 sec (5 sec if main power and aux. power fail at the same time)
 During aux power ride through: no change in the operation of the drive.
 In case of “aux. power loss”-trip, modulation will stop, protective functions remain in operation
 After an "aux. power loss"-trip, the drive will automatically accelerate again to reference speed,
if the automatic start function is enabled. The automatic restart is limited to max. 600sec
(default: 30sec).
 In case aux. power does not return and drive has internal batteries, control will be switched off
after about 15 min.
 Within the 5 sec limit and in case of a simultaneously fail of aux. and main power the drive will
be automatically accelerate again to reference speed 2 seconds after the (both) voltages have
returned.
Aux. power loss ride through
 Note:
Increased risk for self excitation in case of aux. power loss without
simultaneous main power loss.
 After the aux. ride through time is elapsed the inverter stops modulation
 If the motor runs above the self excitation frequency, then during
coasting down the unavoidable consequence would be a major trip
(including MCB open).
 How to extend the aux. power ride through capability:

 For longer ride through times, use UPS with following specification:
 Three phase supply of rated aux. voltage (as specified above)
 8kW power for air cooled converters, 5kW for water cooled converters
Fuseless design

Main Feeder Rectifier DC-Link & Inverter Output Sine
MV Converter Input Prot IGCTs Filter
Breaker
Supply Transformer
& Protection
I>> Prot
MV AC
Induction
Motor
 To protect the system against unnecessary damage

 Protection IGCTs are placed between rectifier and DC-link capacitors –

more than 100 times faster than conventional fuses
 Fuses are known to be costly, unreliable, subject to aging
Output sine filter
 Output sine filter – compatibility with new and existing
motors
 Actively controlled LC low pass filter
 Eliminates virtually all inverter switching harmonics to the motor
 Keeps motor and bearings common mode voltage free
Output Sine Filter
Inverter Motor
Side Side
Inverter output voltage Drive output voltage to the motor

Output sine filter
 Output sine filter – compatibility with new and existing motors
 Motor voltage and current waveforms
 Sinusoidal output waveforms throughout the full operating range

 THD of current and voltage typically below 2%, i.e. far better than required by most
stringent network harmonic standards
Output sine filter
 Output sine filter – compatibility with new and existing
motors
 Motor efficiency as under DOL operation
no motor de-rating required
 No voltage reflections, no common modes
saves motor insulation and bearings
 No high frequency components
use of standard cables
no limitation of cable length
no EMC problems
 No switching harmonics
no additional motor noise

Inverter Topolgy
3-level Voltage Source Inverter (VSI)
Sine Wave
Filter
Standard
DC
AC Induction
Link
Motor
Legend
IGCT with integrated gate driver and freeweeling diode

NPC Diode (Neutral Clamping Diode)
Number of Power Switching Devices: 12 IGCTs

Inverter Switching Patterns
Positive Current:
+ + +
0 Phase 0 Phase 0 Phase
_ _ _
Negative Current:
+ + +
0 Phase 0 Phase 0 Phase
_ _ _
3-Level Inverter Output Voltage
 Phase to Phase Inverter Output Voltage

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

topology
IGCT Technology
Product
IGCT: Integrated Gate Commutated Thyristor

designed for the needs of the MV drives market
• IGCT delivers the benefits of IGBT’s

with the added robustness required for
MV drive applications.
• Conducts like a thyristor
• Switches like a transistor
• Low on-state and switching losses
• high reliability, high efficiency, low parts count

IGCT Technology
Advanced IGCT switching device combines the fast switching of

IGBTs with the proven reliability of GTOs
 Features  Benefits
 Fast switching (up to 20kHz)  High Performance
 Low switching and on-state  High Efficiency
losses
 Snubberless  Low Parts Count
 Integrated gate driver & free  Low Parts Count and High
wheeling diode (ACS 1000) Reliability
Routine Testing
 Rigorous 7 hour, 4 step
testing program
 Including 3 hour load test
 Reduces on-site
commissioning time
 Test Sequence
1.
High Voltage
Insulation Test
0.5 h
2.
Testing of
Controls
1.0 h
3.
Testing of
Power Part
2.5 h
4.
a) Motor Load Test
b) Full Current Test
3.0 h
Local Control Panel
Intelligent Control Panel
CDP 312 R
Easy monitoring - four-line display

Supports maintenance - fault
memory
Removable panel
Quick and easy commissioning with
the parameter copying feature
Selection and parameterization
of application macros
Language: English
Control
 Direct torque control (DTC)

 See next slide
 Scalar Control
 Basic control method for different functionalities:
 Step-up transformer (and synchronised bypass)
 Connection of more than one motor to one converter
 Control of ”very” long cables: 5 ... 20km
 Customer I/Os
 IOEC-Board 2 for remote control & main feeder breaker
control
 IOEC-Board 3 for internal water cooling control

for transformer and motor supervision
 IOEC- Board 4 for optional functions
Control – Core Ideas of DTC
 Direct control of the motor electromagnetic state

 Torque and stator flux are controlled at every control
cycle, and so is the selection of inverter switching;
there exist no predetermined switching patterns
 Exact calculation of the flux vector
 Using an adaptive motor model, based on motor
nameplate data
 Torque control by using hysteresis control

Flying start
READY_TO_CHARGE
General remarks: 0x02
Yes
 State machine controls the start-
No
up procedure MCB On
?
Udc < 50V
?
 For different start modes, certain Yes

No
parts of state machine are used CHARGING
DISCHARGING
0x03
or skipped
 Starting modes of ACS 1000 Charging timer No MCB On No
? ?
 Direct start:
Motor speed always at 0 rpm Yes Yes
when the drive is started

No dUdc > No
Udc > Uon
Fault Ucharge
 Encoder less flying start: ?
?
Motor might still be turning when Fault

Yes Yes
the start command is given.
Close Prot. IGCTs
 Flying start with encoder:
Very fast catch flying start

READY_TO_RUN
0x05
Flying start – encoderless

 Parameters for flying start

 Function needs to be enabled
 No special tuning required
 Required parameters are calculated based on system parameters
 Adjustment of parameters to meet special requirements:
 Speed search start set point:
Typical value: 40% of nominal speed, because the speed of the
motor falls fast from higher speeds. Spinning of a load is typically in
the lower speed range.
 Speed search frequency change:
The change rate of the search frequency can be increased in order

to ramp the search frequency faster through the speed search area.
 Catching a back-spinning load

 Function “Backwards search” to be enabled
 Note:
 As soon the backwards spinning load is detected and the motor is
magnetized, the converter has first to decelerate the motor to 0rpm
and the to accelerate the motor in the forward direction.
 In order to decelerate the converter has to break  energy is
flowing from the mechanical system to the drive.
 ACS 1000 has very limited braking capabilities (2 quadrant drive)
 For higher breaking energy  breaking resistor to be added
Flying start – other starting modes
 Direct start
 Similar to encoderless flying start, but
 No frequency search (part of state machine skipped)
 Magnetization of motor is done at settable frequency
 Flying start with encoder
 similar to direct start, but
 Magnetization of motor is done at measured frequency
Motor Protection
 Motor Over- and Under-Load Protection
 Supervision of motor current within a free programable range
IIdealMot
A
Par.: 42.26
Current Level P9 P9
P8
9 current points (P1 ... P9)
Par.: 42.18 ... 42.26
Overload Trip Current
P7
Overload Alarm Current P6
P5
P4 Underload Alarm Current

P3
Par.: 42.18 P2
Current Level P1 P1
Underload Trip Current
Par.: 42.17
LoadProtStartCurr
Par.: 5.08 Ideal Motor Current (calcutated)
9 frequency points (P1 ... P9) fMot

Hz
Par.: 42.08 ... 42.16
Par.: 42.08 Par.: 42.16
Frequency Level P1 Frequency Level P9
Par.: 42.07
LoadProtStartFreq
Motor Protection
 Phase Unbalance Protection
 Supervision of all three motor phase currents
IMotPhase Par.: 1.18 MotCurrent Phase U
A
(RMS)
Par.: 1.20 MotCurrent Phase W Par.: 1.19 MotCurrent Phase V

(RMS) (RMS)
Par.: 1.21 Motor Phase Unbalance Current

- min. Motor Phase Current)
(Difference = max. Motor Phase Current
Par.: 43.04 MotPhaseUnbalTripCurrent

MotPhaseUnbalTripLim
Par.: 43.03 MotPhaseUnbalAlarmCurrent
MotPhaseUnbalAlmLim
motor phase unbalance alarm (start of delay time)

fMot
Hz
motor phase unbalance trip (start of delay time)
Standards and Certifications
 Standards
 Applicable standards
 Declaration of EU conformity
 UL and cUL Certifications
 For public information, go to:
http://database.ul.com/cgi-
bin/XYV/template/LISEXT/1FRAME/index.htm
 Enter „ACS 1000“ as key words
 ISO 9001:2000, ISO 14001:20004, OHSAS 18001:1999
Additional features
 Programable Customized Supervision Functions
 Possibility to process customer I/Os arithmetically and logically
 “Programed“ by parameter settings
 Backspin Lockout
 Protect the motor from restart within a selectable time
n Pump
rpm Stop
Command Stopped
Par.: 21.12
Backspin Lockout Time
Start inhibited
0 t s
Backspin Lockout active Backspin Lockout not active

Stopping
(ASW1 - Bit 8 = "1") (ASW1 - Bit 8 = "0")
Additional features
 Long Motor Cables

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

ACS 1000(i) Options – Overview
 See also type code for all possibilities and combinations
ACS 1000 Type Code Sheet Example: ACS1044-A3-K0-00-SQ20-E0A0-0C12-0000-00U00-EN

24 Enclosure Class
1 = IP 21 (air cooled standard) 3 = IP 31 (water cooled standard, air cooled option)
2 = IP 22 (air cooled option) 5 = IP 54 (water cooled option)
6 = IP 32 (air cooled option)
4* = IP 42 (air cooled standard option, water cooled only as engineered option)
Precondition:
4 => Pos 5 (Variation) = 1
25 - Input Contactor, fused (for ACS 1000i only)

0 = None
1*= Fused input contactor (IEC-Type - only available up to 6.6kV input voltage)
2*= Fused input contactor (ANSI-Type - only available up to 6.9kV input voltage)
Precondition:
1 => Pos 6 (Input Bridge) = 4 and Pos 8/9 (Frame Size) = A1, A2 or A3 und Pos 32 = 0
2 => Pos 6 (Input Bridge) = 4 and Pos 8/9 (Frame Size) = A1, A2 or A3
26 Bypass Control See Option Sheet

0 = None x = Bypass Control included
 Design and Environmental Requirements

 Coated printed circuit boards
 Corrosion protected busbars (nickled)
 Split cabinet*
 Drive Enclosure
 Higher IP protection: IP22, IP32, IP42 for air cooled drives
IP54 for water cooled drives
 Painting: whole cabinet painted
non-standard colors
thickness can not be changed
 Line Supply Section
 24-pulse rectifier
 Common mode choke*
* Dedicated slide(s) later in this presentation

 Motor Side
 Increased output frequency 82.5Hz*
 Ex-Zone signal interface
 Motor cooling pump/fan control
 Speed feedback
 Motor space heater control
 Converter Cooling
 Redundant cooling fan*
 Redundant cooling pump*
 Glycol cooling
 Raw water control valve (2-way or 3-way)*

 Water Cooling Engineered Options*

 (Bi-directional) Converter Bypass*

 Braking Chopper*
 Floating Ground*
 Control Interface
 IOEC-Board 3 & 4
 PT100 transmitters*
 Fieldbus connections*
 Software
 Application Software Macros
 PID Control
 Master/Follower
 Drive Windows*

ACS 1000(i) Various Services
 Factory Witness Testing

 Visual inspection
 Extended Warranty
 24 / 30 months
 36 / 42 months
 Packing
 Land transport
 Sea worthy packing
 Shipping
 FCA Turgi
 EXW Turgi
 FOB Rotterdam
 Service and Support

 24x365 Supportline*

Drives Window Software Tool
 Displaying system
configuration
 Monitoring actual signal
values
 Viewing and changing
parameters
 Fault logger
 Event logger
 Data logger for fast and
accurate measurements
 Drives control
 Backup and restore

Output Frequency and Field Weakening
Torque  Nominal Frequency Range:
45 … 66 ... 82.5 Hz
 Field Weakening Range:
max. 1 : 1.5
 Both conditions are to be fulfilled !
 E.g.: if Fnom = 50Hz
Then Fmax = 50*1.5 Hz
= 75Hz
FWP Fmax
F [Hz]
=100%
Requirement >45Hz < 1.5 x FWP

: and
< 82.5Hz
Fieldbus Interfaces
Fieldbus System
Ethernet, TCP/IP Backbone
Operation HMI
level HMI
System Bus
Control
level
PROFIBUS-DP PROFIBUS-PA
Device
level
Fieldbus Interfaces
Fieldbus Interfaces with ABB Drives
 Supported fieldbusses
 Profibus
 Modbus
 ModbusPlus
 DeviceNet
 Ethernet
 AF100
- AC70, AC80, AC800  PLC functions
- FCI (CI810 & TB811)  no PLC functions

Common Mode Choke
Main Feeder Breaker Converter Input Rectifier & DC-Link Inverter Output
& Protection Transformer Prot IGCTs Sine Filter
I>> Prot
Common MV AC
Mode Choke
Induction
Motor
 This option is needed if cable length between converter transformer

and ACS 1000 exceeds following limits:
 30 m for ACS 1000, 12-pulse and
 20 m for ACS 1000, 24-pulse.
 If cables are longer than following limits, then please contact PRU:
 200 m for ACS 1000, 12-pulse and
 150 m for ACS 1000, 24-pulse.
Common Mode Choke
 Common Modes inside the Drive System
I_Cf uvw _G
A
35
30
25
20
15
10
Common Modes are produced from every -10
-15
-5
inverter, independent which topology is used -20
-25
and which manufacturer is considered. -30

0 5 10 15 20 25 30
ms
In ACS 1000 they are directed back to the transformer, but kept away
completely from the motor.
Redundant Cooling Fan
 Air Cooled Drives

Dimensions: 2000mm wide, 800mm high

Noise Level: <85 dB (A)
Attention: 7.5% Power derating required !

Redundant Cooling Fan
 Water Cooled Drives Fan 2

 The redundant fan is placed
on top of the drive’s water
cooling unit
 Height about 30cm (however Fan 1
1m clearance needed for
exchanging the fan)
 No power derating required
 Only available in
combination with Redundant
Cooling Pumps
PT100 Transmitters
 Requirement for this option  Available Selections

 If PT100 measurement signal  3 transmitters for motor
shall be connected to the winding temperature
ACS1000 I/Os
 5 transmitters for winding and
bearing temperatures
 6 transmitters for motor
winding temperature
 max. 8 transmitters:
- 6 for winding temperatures
- 2 for bearing temperatures
 On special request up to
10 transmitters possible
(additional channels for transformer
winding temperature and ambient

temperature)
Synchronized Bypass Control
 Single Line Diagram
M
Output 3-Ph
Isolator
Squirrel Cage
Induction Motor
Application Control and
Converter Direct Torque Control (DTC)
Transformer
12-pulse Output
Rectifier Filter
Note: the output isolator has to be a load disconnector for breaking the
current flow between motor / network and sine filter
 Single Line Diagram of a Starting
System for 2 .. 4 Motors
 Start-up Bypass for more than 4

motors possible, however only as
engineered system
 Taking a motor back from line to VSD
operation is possible for max. 2 motors
 Extra cabinet required

 (included in scope of supply)
 Synchrotact, I/O, auxiliary relais
 Not included
 All bypass breakers and output
disconnectors
 Motor protection (only the motor in
VSD operation is protected by drive
controls)
 Overriding controls for coordination of
the different motors

 Extra Cubicle
Section
(on the left hand side of
the drive)
 Scope of supply
 Extra cabinet, 644mm wide on the left hand side of the drive, containing:
 Synchrotact
 All I/Os ond auxiliary relays for bypass breaker and output disconnector controls
 optionally PT for the ACS1000 output voltage
 on request the PT for the MV bus can be delivered as loose component,
but to be mounted within the switchgear
 Not included
 To be part of the drive system:
 All bypass breakers and output disconnectors
 Motor protection (only the motor in VSD operation is protected by drive controls)
 Overriding controls for coordination of the different motors
Braking Chopper
 Electrical
Diagram:
Braking Chopper
 Mechanical
Layout:
644 mm wide
cabinet, installed
on the right hand

side of the drive
Braking Chopper
 Features:
 For use with an external braking resistor (max. cable length 50 m
between chopper and resistor)
 “One size fits all”
 Always air cooled with natural convection
 Main Data:
 Max. braking power is 2.5 MW or 60% of rated drive power,
whatever is more stringent
 Max. braking energy is 75 MWs per hour

Braking Resistor
 Considerations:
 Usually mounted outdoors, using natural convection
 Relevant for basic dimensioning (and pricing):
- max. braking power
- max. braking energy per time interval
- max. voltage
 For specification of the resistance value please contact the PRU in
Turgi
Floating Ground
 Option Floating Ground is designed to run the motor under ground
fault (single fault)
 Always an ”engineered option” (case specific dimensioning
required)
Rst Cst
ACS 1000 Water Cooling Engineered Options
 Special Water Cooling Options
 Flange connections
(instead of standard hose connectors)
 ANSI flange 2’’ / B16.5 / 150 lbs or
DN 50 / PN16
 Flange orientation to top, bottom or side
 Manual shut-off valves on request
 2’’ ANSI flange also for drain connection
available
 Special Water Cooling Systems
 higher cooling water temperatures up to 45°C
 one loop cooling system
 chiller cooled drive cabinet
 IP42 ventilated drive cabinet
 closed cooling system design
 recommended if glycol shall be added
 preferred for one loop systems
 Packages
 fin / fan cooler packages
 for demineralised water cooling circuit (one loop system)
 for raw water cooling circuit (standard two loop system)

 chiller packages
 ACS1000-W Standard W/W HEX
Filter Cooling raw

Q P T water supply
L open analog analog analog from
L system customer side
digital > 4°C,
Power losses water W/W HEX
< 27 °C (38°C)
by
fin/fan cooler,
analog
chillers or
others
Advantages:
M
 Separation between internal demineralised
water and external raw water circuit
 Lowest WCU costs on ACS1000 side
Power losses Air A/W HEX
 ACS1000-W One-loop system < 38°C water temp.
Heater*
Filter
Q P T *Heater needed if
closed analog analog analog
Watercan be below
5°C during Standby
system Customer
side
Power losses water W/W HEX,
fin/fan cooler
Advantages: or chiller
<38°C
 No raw water pumps needed
 No temperature
P control valve on raw water
M
side needed, i.e. minus temperatures possible
analog
by simply adding glycol (derating !)

A/W HEX
Power losses Air

 ACS1000-W One-loop system < 45°C water temp.
Filter Heater*
Q P T *Heater Customer
closed needed if
analog analog analog Watercan be side
system below 5°C water / water
during
Standby HEX
Power losses water or fin/fan
cooler
Advantages: <38°C
 No raw water pumps needed up to 45°C

with derating
 No temperature
P
control valve on raw water
M
side needed, i.e. minus temperatures possible
analog
by simply adding glycol (derating !) Filter
A/W HEX
 Increased water temperatures up to 45°C Autonomous
possible  no need for chiller,
Power losses Air P if max. ambient Digital
compact
chiller (7kW)
temperature below 40°C < 27 °C water

temperature
Example for an ACS1000-W One-loop system
closed system W/A HEX on

fine-water side
External W/W HEX

3-way valve for

water temp control
Example for external W/W HEX
 External W/W HEX Raw water inlet
 Tailored for different

requirements
 Titanium version
 Design for heavily
polluted raw water
possible
 Sea water as raw water Raw water outlet
 Even tube HEX could

be used
 Also redundant HEX’s
possible on request
Manual shut-off valve

 ACS1000-W One-loop system, called “IP42”
Filter Heater*
Q P T *Heater Customer
closed needed if
analog analog analog Watercan be side
system below 5°C water / water
during
Standby HEX
Power losses water or fin/fan
cooler
Advantages: <38°C
 No raw water pumps and no A/W HEX needed up to 45°C

with derating
 Increased
P
water temperatures up to 45°C
M
analog
 feasible up to 40°C max. ambient room Cooling Air from
control room
temperature (power derating above 35°C room
temperature)
Power losses Air
up to 7kW heat
losses into the
control room
ACS 1000 Options 3-Way Raw Water Control Valve
 Location in the Water Cooling Circuit
 Part of the raw water

cooling circuit
 Operated by ACS1000
Controls
Note:
Retrofitting of this option
is not possible !
ACS 1000 Options 3-Way Raw Water Control Valve
 Requirement for this option

 If the raw water flow must not be throttled down to zero
 This is typically the case for any closed raw water cooling system,
like water / air heat exchanger or chiller unit
 The standard 2-way valve is usually only sufficient if the drive is
connected to the plant raw water system (as one consumer among
several others) or if a minimum flow bypass is provided on the
external raw water system side.
ACS 1000 Options Split Cabinet
 Only available for

water cooled drives
 For ease of
transportation into
narrow buildings
 Engineered Option
 Contact PRU for
quotation
ACS 1000(i)
Service and Support
24x365 Service Support
Service Level
1 Field Engineer Customer / Plant
Local & Regional Service

Local SupportLine
Centrally based Support

SupportLine
3
4 Product R&D Appl. R&D

ACS1000 Service Concept
Service Escalation
Level 4 (R&D Resources in Turgi, Switzerland)
Engineering Design Resources
If the problem is not resolved by level 3, the call

is routed to the product development center,
the highest level of service support
Level 3
24x365 SupportLine
If also local efforts fail, a Support Center Experts of ACS1000 available in
operator can be called. A system specialist Turgi, Switzerland
will return the call in 30 minutes. - Emergency Spare Parts Deliveries out of
Logistic Center Helsinki / Finland
Local SupportLine Level 2

If the field engineer does not solve the
problem in two hours, he contacts
Local experts
the local specialist.
Local Field Service Level 1

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

Extension Cord Safety Module 2

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Kai Mossig ACS 1000

 Voltage, Power Range and Main Versions

 Square Torque or Constant Torque applications, e.g.:

 Available Output Voltage and Power Range

6.0 6.9 8.0 13.8

ACS 1000 MV Variable Frequency Drive

Supply Side DC Link and Inverter Sine Wave

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

 Fuseless Design, using Protection IGCTs

315 - 2000kW Applications

Cooling Fan Inverter

Control Rectifier DC Link and

Noise Level: <75 dB (A)

Air cooling circuit specification type of ACS 1000

nominal cooling air flow 1.7 m3/sec 2.5m3/sec

2000 - 5000kW Applications

4200 mm for W1 frame size

Water Cooled Range:

315 – 2000kW Applications

ACS1000i specific All components identical with

Line Isolator 5-winding 24-pulse DC-Link Inverter Output Motor

 Self-commutated 3-level VSI-NPC

 Typically supply from a feeder of customer’s MV

 no need for any control wiring between drive and

 Supply voltage tolerance + 10 / - 5%

 Supply frequency tolerance ± 5%

 5-winding transformer for 24-pulse harmonic line performance

 efficiency of 98 ... 98.5%

ABB type POLIM-D

ACS 1000i standard feature !

 24-pulse diode located in front

 Standard supervision of:

(one for middle winding)

• Standard: 12 pulse- transformer and diode bridge

 Total power factor: 0.95 constant over speed range

 Supply Voltage Variation

 Aux. Supply (3-Phase)

 Main power loss ride through  Auxiliary power loss ride

ACS 1000 MV Variable Frequency Drive

Auxiliaries, Control, protection & supervision

Aux. Power Control Gate unit Cooling Add.

• Fast response to mains UDC

• Controlled operation during

fOUT = output frequency

 How to extend the aux. power ride through capability:

ACS 1000 MV Variable Frequency Drive

 To protect the system against unnecessary damage

 Protection IGCTs are placed between rectifier and DC-link capacitors –

Inverter output voltage Drive output voltage to the motor

 Sinusoidal output waveforms throughout the full operating range

no additional motor noise

3-level Voltage Source Inverter (VSI)

IGCT with integrated gate driver and freeweeling diode

Number of Power Switching Devices: 12 IGCTs

0 Phase 0 Phase 0 Phase

0 Phase 0 Phase 0 Phase

 Phase to Phase Inverter Output Voltage

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

IGCT: Integrated Gate Commutated Thyristor

• IGCT delivers the benefits of IGBT’s

• high reliability, high efficiency, low parts count

Advanced IGCT switching device combines the fast switching of

Easy monitoring - four-line display

 Direct torque control (DTC)