ABB ACS 6000 Tech Catalog RevD

ACS 6000 Technical Catalog
Water-cooled ACS 6000
ABB
ABB
Table of Contents
List of Figures 9
List of Tables
13
Chapter 1 - Overview 1.1 1.2 1.3 1.4 1.5 1.6 Introduction Modular design Technological highlights Standard applications Benefits for the customer CE marking
15 15 16 17 18 19 21
Chapter 2 - Types and applications 2.1 2.2 2.2.1 2.2.2 2.2.3 2.3 2.3.1 2.3.2 2.3.3 General The ACS 6000 drive types Single-motor drives Multi-motor drive Redundant configurations Application examples Marine propulsion and thruster drives Rolling mill applications Mining applications
23 23 23 23 25 27 27 27 30 35
Chapter 3 - Functional description, operation 3.1 3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.3 3.3.1 3.3.2 3.4 3.4.1 General Standard control functions Direct torque control Motor control functions Active rectifier control functions Application control functions Operation and diagnostics Local and remote operation Standard diagnostic functions Standard protection functions General
37 37 37 37 41 42 42 44 44 49 49 49
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3.4.2 3.4.3 3.4.4 3.4.5 3.5 3.6 Protection functions related to drive system Internal converter protection functions External protection functions Manually initiated protection functions Other features Optional features 50 52 52 53 53 54
Chapter 4 - Hardware design, technology and configuration 4.1 4.2 4.2.1 4.2.2 4.2.3 4.3 4.4 4.4.1 4.4.2 4.4.3 4.5 4.6 4.6.1 4.6.2 4.7 Overview Technology Common DC bus Fuseless design IGCT power semiconductor Cabinet layout Cabinet design Mechanical design Electromagnetic compatibility (EMC) Safety aspects Busbars and grounding Auxiliary supply system 3-phase supply 3-phase supply and separate UPS for control power Cooling system
55 55 55 55 60 60 61 62 62 63 63 64 65 65 66 67
Chapter 5 - Hardware design, description of converter units 5.1 5.2 5.3 5.3.1 5.3.2 5.3.3 5.4 5.4.1 5.4.2 5.4.3 5.5 5.5.1 5.5.2 5.6 5.6.1 5.6.2 Overview Available modules Line supply unit (LSU) Overview 12-pulse LSU 6-pulse LSU Active rectifier unit (ARU) Overview Main components Circuit diagram Inverter unit (INU) Overview Circuit diagram Capacitor bank unit (CBU) Overview Main components
69 69 69 70 70 70 73 74 74 76 77 78 78 79 80 80 80
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5.6.3 5.7 5.7.1 5.8 5.8.1 5.8.2 5.9 5.9.1 5.9.2 5.9.3 5.9.4 5.9.5 5.9.6 5.9.7 5.9.8 5.9.9 5.10 5.10.1 5.10.2 5.11 5.11.1 5.11.2 5.11.3 5.12 5.12.1 5.12.2 5.12.3 5.13 5.13.1 5.13.2 5.13.3 5.14 5.14.1 5.14.2 5.14.3 5.15 Circuit diagram Terminal unit (TEU) Overview Control unit (COU) Overview Main components Water cooling unit (WCU) Overview Water cooling system WCU types and sizes Main components Cooling control Raw water connection Technical data Options for WCU Air-to-air heat exchangers Customer interface unit (CIU) Overview Main components Input filter unit (IFU) Overview Main components Circuit diagram Voltage limiter unit (VLU) Overview Main components Circuit diagram Resistor braking unit (RBU) Overview Main components Circuit diagram Braking chopper unit (BCU) Overview Main components Circuit diagram Excitation Unit (EXU) 82 82 82 83 83 86 87 87 87 88 91 92 93 93 93 93 94 94 95 96 96 96 97 97 97 98 99 99 99 100 101 101 101 101 102 102
Chapter 6 - Control system and process interfaces 6.1 6.2 6.2.1 6.2.2 6.3 6.3.1 Overview Hardware and structure of the control system Hardware Configuration examples Local control devices CDP local control panel
103 103 103 103 105 109 109
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6.3.2 6.4 6.4.1 6.4.2 6.5 6.5.1 6.5.2 6.5.3 6.6 6.6.1 6.6.2 6.6.3 6.6.4 6.6.5 6.6.6 6.7 CDP control panels, control switches and indicator lamps Fieldbus interfaces Fieldbus types Signals Hardwired process I/Os Standard S800 I/O modules Customer control signals Interface configurations Control software Control software structure Operating system Motor and rectifier control software Fixed application software FCB application software Panel application software Control options 110 114 114 115 118 118 119 119 122 122 123 123 123 124 124 124
Chapter 7 - Engineering information 7.1 7.2 7.3 7.3.1 7.3.2 7.4 7.5 7.6 7.7 7.8 7.8.1 7.9 General Main circuit breaker Main transformer Main transformer for ARU Main transformer for LSU ARU synchronization transformer Asynchronous motor requirements Synchronous motor requirements Excitation supply Selection of power cables Power cable dimensioning Control cabling
125 125 125 126 126 126 126 126 126 127 127 127 128
Chapter 8 - Installation guidelines 8.1 8.2 8.3 8.4 8.5 8.6 8.6.1 8.6.2 8.6.3 8.6.4 General Ambient conditions Transport Installation site requirements Raw water flanges Power cable installation, grounding and shielding Sealing system for power cable entry Connecting ARU to supply transformer Connecting LSU to supply transformer Connecting motor to INU
129 129 129 129 131 132 133 133 134 136 137
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8.7 8.8 Equipment grounding Installation of auxiliary power and control cables 137 138
Chapter 9 - Ordering information 9.1 9.2 9.2.1 9.2.2 9.2.3 9.3 9.4 9.5 9.6 General Drive selection Required application data Configuration procedure Configuration rules Type code Option list External system data Technical data
141 141 141 141 141 142 142 142 142 143
Chapter 10 - Options 10.1 10.2 10.3 10.4 10.5 10.5.1 10.5.2 Converter hardware Options for WCU Converter software Service and diagnostics Optional customer interfaces I/O with option CIW1 (standard software) I/O with option CIW2 and CIW3 (project specific SW) 10.5.3 I/O with option CIUe 10.5.4 AC 80 / AC 800 controller 10.6 Marine version 10.7 Transportation, installation and commissioning 10.8 Training 10.9 Testing 10.10 Documentation
145 145 146 147 147 150 150 150 150 150 151 153 153 153 154
Index
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List of Figures
Figure 1-1 Figure 1-2 ACS 6000, typical marine configuration with air-to-air heat exchanger ACS 6000, typical standard configuration with active rectifier without air-to-air heat exchanger Typical examples for basic configurations Single-motor drives, basic configurations Single-motor drive, SD type, example with active rectifier Example of a standard multi-drive configuration Example of system configuration for offshore drilling rig Redundant main propulsion system Configuration for a service vessel Hot rolling mill train: overview Rougher mill train Reversing steckel mill Sendzimir mill Mine hoist Overland conveyor DTC block diagrams DTC: typical dynamic speed response DTC vs. PWM: Typical torque response times Typical ramp shapes Setting the control panel to local / remote Start sequence with ARU Start sequence with LSU Stop and off sequence with ARU Stop and off sequence with LSU Emergency off sequence Stall region of the motor Common DC bus principle Converter principle diagram Phase voltage created by ARU Vector control principle Active rectifier control block diagram IGCT ACS 6000 basic configuration with LSU ACS 6000 basic configuration with active rectifier and input filter unit Arrangement of busbars "AC safe line" auxiliary concept 3-phase auxiliary supply and AC UPS 15
Figure 1-3 Figure 2-1 Figure 2-2 Figure 2-3 Figure 2-4 Figure 2-5 Figure 2-6 Figure 2-7 Figure 2-8 Figure 2-9 Figure 2-10 Figure 2-11 Figure 2-12 Figure 3-1 Figure 3-2 Figure 3-3 Figure 3-4 Figure 3-5 Figure 3-6 Figure 3-7 Figure 3-8 Figure 3-9 Figure 3-10 Figure 3-11 Figure 4-1 Figure 4-2 Figure 4-3 Figure 4-4 Figure 4-5 Figure 4-6 Figure 4-7 Figure 4-8 Figure 4-9 Figure 4-10 Figure 4-11
16 17 24 25 26 28 29 30 31 32 33 34 35 36 38 40 40 41 44 45 46 47 48 48 51 56 57 57 58 59 60 61 62 64 66 66
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Figure 4-12 Figure 4-13 Figure 5-1 Figure 5-2 Figure 5-3 Figure 5-4 Figure 5-5 Figure 5-6 Figure 5-7 Figure 5-8 Figure 5-9 Figure 5-10 Figure 5-11 Figure 5-12 Figure 5-13 Figure 5-14 Figure 5-15 Figure 5-16 Figure 5-17 Figure 5-18 Figure 5-19 Figure 5-20 Figure 5-21 Figure 5-22 Figure 5-23 Figure 5-24 Figure 5-25 Figure 5-26 Figure 5-27 Figure 5-28 Figure 5-29 Figure 5-30 Figure 5-31 Figure 6-1 Figure 6-2 Figure 6-3 Figure 6-4 Figure 6-5 Figure 6-6 Figure 6-7 Figure 6-8 Figure 6-9 3-phase auxiliary supply and DC UPS Principle diagram of the water cooling circuit Cabinet layout of 12-pulse LSU Circuit diagram of 12-pulse LSU Cabinet layout of 6-pulse LSU with IRU Circuit diagram of 6-pulse LSU with IRU ARU cabinet layout Phase module with IGCTs ARU local control and monitoring equipment ARU circuit diagram 3 and 5 MVA Units 7, 9 and 11 MVA INUs Circuit diagram of 7, 9 and 11 MVA INUs Circuit diagram of 3 and 5 MVA units CBU cabinet layout CBU circuit diagram TEU (1000 mm wide) COU control swing frame installed in a TEU (typical configuration) Reverse side of COU doors (typical configuration) Principle illustration of water cooling circuit WCU - closed to atmospheric pressure Principle flow diagram of a WCU with a closed circuit WCU open to atmospheric pressure Flow diagram of WCU with open circuit Roof heat exchangers CIU, typical cabinet layout IFU cabinet layout IFU circuit diagram VLU cabinet layout VLU circuit diagram RBU cabinet layout RBU circuit diagram BCU circuit diagram Single-motor drive with ARU Single-motor drive with ARU (example with water-cooled EXU) Single-motor drive with LSU Multi-motor drive with ARU Multi-motor drive with double ARU Single-motor drive with double ARU and double INU CDP control panel ARU control panel INU control panel 67 67 71 72 73 74 75 76 77 77 78 79 79 80 81 82 83 84 85 87 88 89 90 91 94 95 96 97 98 99 100 101 102 105 106 107 108 108 108 110 111 112
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Figure 6-10 Figure 6-11 Figure 6-12 Figure 6-13 Figure 6-14 Figure 6-15 Figure 6-16 Figure 7-1 Figure 8-1 Figure 8-2 Figure 8-3 Figure 8-4 Figure 8-5 Figure 8-6 Figure 8-7 Figure 8-8 Figure 8-9 Figure 8-10 Figure 8-11 Figure 10-1 Figure 10-2 Figure 10-3 Figure 10-4 Figure 10-5 Figure 10-6 Figure 10-7 Figure 10-8 Figure 10-9 Control panel on additional control units Grounding switch on CBU S800 I/O station S800 I/O configuration of an ACS 6000 single drive ACS 6000 single-motor drive with option CIW1 Typical ACS 6000 multi-motor drive with option CIU2 Software block diagram of the AMC controller Excitation transformer schemes for multi-motor drives Cabinets with base frame and without door handles Cabinets with base frame and marine-type door handles Cabinets without base frame Space requirements (dimensions in mm) Flanges Power cable entry with roxtec sealing system ARU side cabling LSU side cabling INU side cabling TEU, connection to system ground Control cable entry with roxtec sealing system Output switch types Leakage sensor Typical DriveWindow display ACS 6000 with DriveMonitorTM installed in a console S800 I/O configuration with AC 80 / AC 800 Marine version Door arrester Roof fixings Roof connecting pieces 113 114 118 119 120 121 122 127 130 130 130 131 133 134 135 136 137 138 138 145 146 148 149 151 151 152 152 153
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List of Tables
Table 2-1 Table 3-1 Table 4-1 Table 6-1 Table 6-2 Table 6-3 Table 6-4 Table 7-1 Case study: power requirements of a sendzimir mill with ACS 6000 DTC versus current vector control IGCT technology compared to GTO and IGBT Fieldbus adapters Basic data exchange between AMC and process control: analog and binary inputs Basic data exchange between AMC and process control: analog and binary outputs S800 I/O modules Control cable requirements 34 39 61 114 116 117 118 128
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Chapter 1 - Overview
1.1 Introduction
The 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
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Figure 1-2
ACS 6000, typical standard configuration with active rectifier without air-to-air heat exchanger
1.2
Modular design
The 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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Single drive with diode rectifier
Multi-drive with active rectifier
Redundant drive with diode rectifier (planned solution)
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 highlights
The 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
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Acccurate static speed and torque control. The Integrated Gate Commutated Thyristor (IGCT) 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.
Integrated gate commutated thyristor
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 Common DC bus
The Line Supply Unit designed for two-quadrant operation maintains the power factor at 0.95 in the whole operating range. 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 applications
The ACS 6000 provides the optimum solution for marine and industrial medium voltage drive applications. Typical fields of applications are: Marine Oil and gas Metals and mining General industry Main propulsion systems Thruster drives Compressors Pumps Rolling mills Mine hoists Overland conveyors Crushers and mineral mills Variable speed fans and pumps Pump storage plant drives
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Teststand.
1.5
Benefits for the customer

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.
Maximum availability
Low energy costs are achieved by: Minimal reactive power consumption
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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: What you need is what you get The maintenance or replacement of redundant cooling pumps can be done on the running system. Air-to-air heat exchanger.
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 documentation.
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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 communication 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 marking
The 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 General
This 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 drives

Single-motor configurations are commonly used in applications which require large and independent drives, such as: Basic configuration 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.
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.
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B
Aux. power Mains Synchronization voltage Aux. power
Mains
Mains
D
Aux. power Excitation power
Mains Synchronization voltage Aux. power Excitation power
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 with multiple 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.
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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 drive

Multi-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
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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).
Mains
Aux. power Synch. reference Excitation power
Figure 2-3
Example of a standard multi-drive configuration
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2.2.3 Redundant configurations
The 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 applications. 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 drives

Electric propulsion is widely used in todays 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: Dynamic positioning of floating vessels 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.
Figure 2-4 shows a typical example for a dynamically positioned offshore drilling rig. It is equipped with four ACS 6000 single drives.
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Mains Aux. power
Mains Aux. power
Mains Aux. power
Mains Aux. power
Figure 2-4 Propulsion and thruster for shuttle and service vessels
Example of system configuration for offshore drilling rig
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.
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Mains
Mains
Aux. power
Mains
Mains
Aux. power
Aux. power
Figure 2-5 Main propulsion with azipod thrusters
Redundant main propulsion system
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.
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Mains Aux. power Aux. power
Mains
Figure 2-6
Configuration for a service vessel
2.3.2 Rolling mill applications

Metals 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: Hot rolling mill train Fast and precise torque and speed control under varying loads Full four-quadrant operation with active rectifier Reduced energy consumption with common DC bus.
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.
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Edger mill Rougher mill
Crop shear
Reversing steckel mill
Hot tandem mill
Figure 2-7 Rougher mill train
Hot rolling mill train: overview
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.
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Mains Synch. reference
Figure 2-8 Reversing steckel mill
Rougher mill train
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.
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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.
Mains
Synch.reference
Aux. power
Figure 2-9 Sendzimir mill
Reversing steckel 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.
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Mains
Synch. reference
Figure 2-10 Sendzimir mill Table 2-1 Case study: power requirements of a sendzimir mill with ACS 6000
Estimated power requirement Main drive Tension reel 1 Tension reel 2 Total supply with individual drives Total supply with common DC bus 4 MW with 200% overload capability 4 MW with 200% overload capability 4 MW with 200% overload capability 3 x 4 MVA with 200% overload capablity Converter rating 9 MVA 9 MVA 9 MVA 3 x 9 MVA = 27 MVA
1.2a x 4 MVA with 200% overload capability
2 x 7 MVA = 14 MVA
a. Dimensioning factor
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2.3.3 Mining applications
The 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
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Overland conveyor
Long overland conveyors may have an overall length of several kilometers. In terrains with long declining sections high braking capabilities 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.
Mains
Aux. power Synch. reference
Figure 2-12 Overland conveyor
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Chapter 3 - Functional description, operation
3.1 General
This 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 other documents Summary of references to linked documents in this chapter: Appendix - Technical data
3.2
Standard control functions

The 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 microprocessor 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 control

Direct 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.
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Torque reference Speed reference Speed control Torque reference controller Torque and flux comparator Switching logic
Actual speed
Switch positions Motor model Voltage Current
Asynchronous motor
Torque reference Speed reference Actual speed & position Speed control Torque reference controller Torque and flux comparator Switching logic
- Motor model - Excitation control
Switch positions Voltage Current
Synchronous motor
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 s. 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 s. Switching takes place whenever required while in conventional 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.
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The torque response times are up to ten times faster than with conventional control methods such as current vector control. This results in minimum torque ripple and most accurate static speed and torque control. DTC versus current vector control Table 3-1 DTC versus current vector control
Direct torque control (asynchronous motor) Motor control variables Switching is based on core motor variables flux and torque
Direct torque control (synchronous motor) Switching is based on core motor variables flux and torque
Vextor control
Switching is based on the separate control of magnetic field and torque producing current components Mechnical speed is essential. Requires shaft speed and postion (measured or estimated)
Requirements for speed encoder
Shaft speed and position are not required (only high performance applications as for example in the mining and metal industry require speed encoders Each inverter switching process is determined separately (every 50 s)
Mechnical speed is essential. Requires shaft speed and postion (measured or estimated)
Maximum inverter response time
Each inverter switching process is determined separately (every 50 s)
Inverter switching is based on average references to a pulse width modulator resulting in delays in response and unnecessary switching Torque step rise time closed loop: 10 to 20 ms sensorless: 100 to 200 ms
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
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 inaccuracies 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.
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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.
PWM with encoder Static speed error Dynamic speed error 0.01 % 0.3 % sec DC drive with encoder 0.01 % 0.3 % sec DTC with encoder 0.01 % 0.2 % sec
Speed (rpm) Torque
Torque (kNm)
Speed Value depending on process Time
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. Typical torque step: response times at 70% speed DTC: 3 ms PWM flux vector: 1020 ms PWM: > 150 ms (scalar control) Torque: DTC PWM
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).
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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 applications. The dynamic speed control error is typically + 0.20.5 % 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 and deceleration ramps
The converter provides user-selectable acceleration and deceleration ramps.

Max
0 Speed reference Speed reference change limited by linear ramp Speed reference change limited by S-curve ramp Acceleration time Ramp shape time
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 control limitations
Parameter adjustable minimum and maximum limits can be set for speed and torque output.
3.2.2.2 Direct torque control features Direct torque control related settings By setting the appropriate parameters, maximum and/or minimum limits can be defined for: Frequency Motor current Inverter overload
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Motor model Excitation control Speed and rotor position
Load angle DC voltage.
The motor model produces exact actual values of torque and flux, based on measured motor current and DC link voltages. The excitation current is controlled in a way that the power factor of synchronous motors is 1. Rotor speed and position of a synchronous motor are monitored continuously 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 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 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.
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 breaker control 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.
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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.
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3.3
Operation and diagnostics
3.3.1 Local and remote operation

The 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 illuminated 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).
1 L -> StateINU Motor SP POWER
0.0 rpm ReadyOn 0 rpm 0.0 kW
-> 1 StateINU Motor SP POWER
0.0 rpm ReadyOn 0 rpm 0.0 kW
Figure 3-5 Local control
Setting the control panel to local / remote
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. 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. The local emergency off buttons on the front doors of the control unit(s) remain active in local and in remote mode. The converter can be started and stopped either manually from the local control panels or from remote overriding control.
Remote control
Emergency off Start and stop sequences
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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. ARU control INU control
NOT RDY ON
NOT RDY ON
- No fault - Aux supply on - Grounding switch ...open - ARU RDY ON - WCU ok - Doors closed - etc. ON (pushbutton) remote: ON
RDY ON
- No fault - Aux supply on
RDY ON
Charge DC link Close MCB Close EXU contactor (SD)
- MCB closed
RDY RUN
Local: START (CDP ARU) Remote: automatically

RDY RUN Start modulation
Local: START (CDP INU) Remote: RUN

Start modulation
RDY REF
RDY REF
Operation according to setpoint
Figure 3-6
Start sequence with ARU
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INU Control
NOT RDY ON
- No fault - Aux supply on - Gound switch open - WCU ok - Doors closed - etc. RDY ON
ON (pushbutton) remote: ON
Charge DC link Close MCB Close EXU contactor (SD)
RDY RUN
Local: START (CDP INU) Remote: RUN

Start modulation
RDY REF
Operation according to setpoint
Figure 3-7 3.3.1.3 Stop sequence
Start sequence with LSU
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.
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ARU control
RDY REF
INU control
RDY REF Local: STOP (CDP INU) Remote: RUN Ramp down speed Stop modulation
RDY REF
RDY RUN
Local: OFF (pushbutton) remote: OFF
(from master INU)
Open MCB (1st INU) Open EXU contactor (SD)
Stop modulation
Discharge DC link
RDY ON
RDY ON
Figure 3-8
Stop and off sequence with ARU
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INU control
RDY REF
Local: STOP (CDP INU) Remote: RUN Ramp down speed Stop modulation
RDY RUN
Local: OFF (pushbutton) remote: OFF
Open MCB (1st INU) Open EXU contactor (SD)
Discharge DC link
RDY ON
Figure 3-9 3.3.1.4 Emergency off sequence
Stop and off sequence with LSU
The converter is switched off immediately if the Emergency OFF button is pressed. ARU control
RDY REF
INU control
RDY REF
Emergency OFF
Stop modulation
Open MCB (1st INU) Open EXU Stop modulation
Coast ramp down
NOT RDY ON
NOT RDY ON
Figure 3-10 Emergency off sequence
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3.3.2 Standard diagnostic functions
Actual signal monitoring
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 General
All 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.
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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 system

The 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 protection functions 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 undervoltage 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 protection functions 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.
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Torque Stall region
Tm.a
Stall frequency
f (Hz)
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 conditions 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:
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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. Cooling circuit Printed Circuit Board (PCB) self monitoring
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.
Communication monitoring
The status of all communication links is monitored. If a fault is detected, a trip is initiated.
3.4.4 External protection functions

Inputs 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).
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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 features
The converter software version, the production date of the individual version, and the serial number can be displayed. 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. The user can prevent unwanted parameter adjustment by activating the parameter lock.
Converter information Door interlocking
Parameter lock
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3.6
Optional features
See Chapter 10 - Options for information.
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Chapter 4 - Hardware design, technology and configuration
4.1 Overview
This 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. Links to other documents Summary of references to linked documents in this chapter: ACS 6000 Outline Drawings Appendix - Technical data Appendix - Applicable codes and standards
4.2
Technology
4.2.1 Common DC bus

The 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.
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AC line voltage Rectifier Inverter
=
Rectifier
=
Inverter
Inverter AC line voltage Inverter
=
Rectifier Inverter
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.
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Operating principle
Chapter 4 - Hardware design, technology and configu-
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). Energy flow in driving mode
AC line voltage Voltage imposed by ARU DC link voltage
ARU =
INU =
Energy flow in braking mode 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. U ARU
Figure 4-3
Phase voltage created by ARU
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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. trans ARU line 1 ARU q trans trans line line 1 ARU line line
Block diagram
ARU
1 ARU
Equivalent circuit diagram
Phasor diagram
Figure 4-4 Power factor control
Vector control principle
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 pulse patterns
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. 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.
Control block diagram
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DC link voltage control Q ref UDC ref Vector control Modulator (optimized pulse patterns) IA,B,C Meas. UDC+ UDC-
UA UB UC
Synchronization (PLL)
Figure 4-5 4.2.1.3 Line supply unit
Active rectifier control block diagram
The Line Supply Unit (LSU) features a diode rectifier which is available in two versions: 6-pulse diode rectifier 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. Various combinations of synchronous and asynchronous motors are possible. The number of system components as well as the footprint can be reduced.
Multi-motor configurations
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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 design

The 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 components than fuses. In the event of an overcurrent, protection firing is triggered and the fault clearing is initialized in less than 25 s, 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 semiconductor

The 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
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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
High voltage IGBT High switching frequency Low switching losses Snubberless Modular design IGCT advantages High blocking voltage High switching frequency Low conduction losses Snubberless Proven reliability Allows compact and modular equipment design Simple topologies with low parts count Snubberless
GTO thyristor Switching technology High blocking voltage Low on-stste losses
Equipment design
Proven reliability Compact Fuseless design
4.3
Cabinet layout
The 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.
LSU
TEU/COU Figure 4-7
INU
CBU
WCU
ACS 6000 basic configuration with LSU
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ARU
IFU Figure 4-8
TEU/COU
INU
CBU
VLU
WCU
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).
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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 Protective earth (PE) Cabinet labelling The cabinet temperature is monitored by a thermostat. The PE busbar (protected earth) is installed through all cabinets (see 4.5 Busbars and grounding). Danger areas are clearly marked with warning labels.
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4.5
Busbars and grounding

AC and DC power connections within converter cabinets are made with copper busbars. Cable entry from top
Cable entry from bottom Connecting point of system ground Figure 4-9 AC busbars Arrangement of busbars
PG to PE connection in CBU
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). It is important that the drive is properly grounded to maintain safety and to ensure smooth functioning of the equipment. For this reason, the drives 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.
Safety ground
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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 system

The 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 supply

The 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.
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380 - 690 VAC (No safe line)
To other drive sections
Charging Unit
Figure 4-10 "AC safe line" auxiliary concept
4.6.2 3-phase supply and separate UPS for control power

The 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 capabilities 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
380 - 690 VAC 110 / 120 / 230 VAC from ext. UPS (AC safe line)
Charging Unit
Figure 4-11 3-phase auxiliary supply and AC UPS
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380 - 690 VAC 110 / 220 VDC from ext. UPS (DC safe line)
Charging Unit
Figure 4-12 3-phase auxiliary supply and DC UPS
4.7
Cooling system
The 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.
Cooling pumps Heat exchanger Figure 4-13 Principle diagram of the water cooling circuit
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Chapter 5 - Hardware design, description of converter units
5.1 Overview
This chapter provides a description of each individual unit. Detailed information is given on the cabinet layout, the available versions as well as on the monitoring and protection devices. Links to other documents Summary of references to linked documents in this chapter: ACS 6000 Outline Drawings Appendix - Technical data Appendix - Applicable codes and standards
5.2
Available modules
The 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 incorporated 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)
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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 configuration.
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 Overview
The 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 LSU

The 12-pulse LSUs as illustrated in Figure 5-1 are used in combination with a line-side converter transformer.
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Chapter 5 - Hardware design, description of converter
Cable duct and control section
di/dt limiting reactors Rectifier monitoring unit Snubber capacitor
Diode stacks of 12-pulse rectifier (including crowbar)
Pulse transformer
Snubber resistors
Water inlet tube Safety ground busbar 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
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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): 12-pulse diode rectifier 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

Thyristor crowbar di/dt choke DC (+)
1L1 1L2 1L3
Rnp DC (NP)
2L1 2L2 2L3 di/dt choke DC (-) Diode rectifier Snubber circuit Diode rectifier monitoring unit Pulse interface board To / from INU
Figure 5-2
Circuit diagram of 12-pulse LSU
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5.3.3 6-pulse LSU
The 6-pulse LSUs are designed for applications without converter transformer 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
IRU
LSU
Terminal section
di/dt limiting reactors Diode stacks of 6-pulse rectifier (including crowbar)
Snubber resistors
Pulse transformer
Water inlet tube Safety ground bar 3-phase reactor Figure 5-3 5.3.3.1 Main components The IRU/LSU consists of the following main components (refer also to Figure 5-4): IRU LSU 3-phase input reactor Terminal section for input cables 6-pulse diode rectifier Cabinet layout of 6-pulse LSU with IRU
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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 IRU LSU

Thyristor crowbar di/dt choke DC (+)
1L1 1L2 1L3
di/dt choke DC (-) Diode rectifier with snubber circuit Diode rectifier Monitoring unit To / from INU
Pulse interface board
Figure 5-4
Circuit diagram of 6-pulse LSU with IRU
5.4
Active rectifier unit (ARU)
5.4.1 Overview
The 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)
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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 configurations.
Gate unit supply Voltage measurement Phase modules
Water tubes
Anti-saturation equipment
Safety ground bar
Figure 5-5
ARU cabinet layout
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5.4.2 Main components

The 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. Cooling water outlet
Rear busbar stubs IGCTs Figure 5-6 Antiparallel diodes Phase module with IGCTs Cooling water inlet
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
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Anti-saturation equipment (ASE) preventing the converter transformer 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.
FSCD board di/dt choke DC (+)
Rclamp
L1,2,3
EMC filters
DC (NP)
Rclamp
DC (-) HVD board
di/dt choke FSCD board Gate firing pulses L1,2,3
GUSP
ASE board
CMVI board
INT board
COU Other INT
Figure 5-7
ARU local control and monitoring equipment
5.4.3 Circuit diagram

DC (+)
L1 L2 L3
DC (NP)
DC (-)
EMC filter (if without IFU)
Phase modules
Clamping circuit
Figure 5-8
ARU circuit diagram
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5.5
Inverter unit (INU)
5.5.1 Overview
The INU converts the DC voltage to the AC motor voltage. The selfcommutated, 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.
Phase modules of the inverter
Control unit (COU)
Terminal unit (TEU) behind control unit 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.
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Phase modules
Figure 5-10 7, 9 and 11 MVA INUs

DC (+)
DC (NP)
L1 L2 L3
DC (-)
Clamping circuit
Phase modules
EMC filter
Figure 5-11 Circuit diagram of 7, 9 and 11 MVA INUs
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DC (+)
L1 L2 L3 DC (NP)
DC (-)
Clamping circuit
Phase modules
EMC filter
Figure 5-12 Circuit diagram of 3 and 5 MVA units
5.6
Capacitor bank unit (CBU)
5.6.1 Overview
The 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.

The 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)
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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
Cable duct
Grounding switch DC busbars
DC link capacitors Charging unit Dummy capacitor
Connection PE - PG Water inlet tube Safety ground busbar Figure 5-13 CBU cabinet layout
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Capacitors Charging unit
DC(+) DC(NP) DC(-)
Grounding switch
PE
Figure 5-14 CBU circuit diagram
5.7
Terminal unit (TEU)
5.7.1 Overview
Mains 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 incorporated 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.
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Separate TEU for 11 MVA continuous power INUs (no combination with other units).
Ground terminals for grounding set AC busbars Phase designation Roxtec frame Power cable entry section (bottom)
Power ground busbar Safety ground busbar Ground terminals for grounding set Swing frame of Control Unit (COU) open Figure 5-15 TEU (1000 mm wide)
5.8
Control unit (COU)
5.8.1 Overview
The 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.
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Position (gray) encoder interface* 24 VDC power supply units Speed encoder interface* Main circuit breaker control board S800 I/O modules 24 VDC distribution terminals
Safety relays of emergency off circuit INU operation prevention devices* Timer relays* Auxiliary relays*
Auxiliary relays for main circuit breaker control Insulation monitor* 230 VAC distribution terminals Thermostats for: cabinet fan unit cabinet temperature Auxiliary contactors
Circuit breaker for charging transformer
Miniature circuit breakers* 230 VAC socket
Synchronizing equipment for ARU**
Auxiliary power supply equipment*
PE busbar
* option, depends on the configuration of the frequency converter ** only converters with ARU (Active Rectifier Unit)
Figure 5-16 COU control swing frame installed in a TEU (typical configuration)
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2
Fan unit Fan unit
Branching unit* Redundant drive interface*
Local control panel (see section 6.5.1 for details) 24 VDC distribution terminals
Branching unit*
INT board** AMC board*** Pocket for documentation INT board**** AMC board
* 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
Figure 5-17 Reverse side of COU doors (typical configuration)
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The hardware components of a COU are mounted on a swing frame. The type and number of the fitted components are determined by the configuration 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.

The 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 interfaces, 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.
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5.9 Water cooling unit (WCU)
5.9.1 Overview
The 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, roofmounted air-to-air heat exchangers are used to remove the heat from nonwater cooled components inside the power sections of the converter (see section 5.9.9 Air-to-air heat exchangers).
5.9.2 Water cooling system

The 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 accessible 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. The water treatment circuit is part of the internal circuit and continuously purifies the cooling water of the internal circuit to keep the conductivity at a low level. The circuit also includes a fill-up valve. The external water circuit containing raw water transfers the heat losses from the water-to-water heat exchanger to the exterior.
2.
3.
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5.9.3 WCU types and sizes

Water 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
Cable duct
Water pumps Heat exchanger Ion exchange vessel Control swing frame
Figure 5-19 WCU - closed to atmospheric pressure
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Expansion vessel
5 1
Deaeration vessel
2 6
Make-up water ISO-R 1/2
Drain hose 12
Figure 5-20 Principle flow diagram of a WCU with a closed circuit
1 2 3 4
from converter pipe DN 80 from EXU hose nipple 26.5 to EXU hose nipple 26.5 to converter pipe DN 80
5 6 7 8
outlet to cooler counter flange DN 50 / ANSI 2" inlet from cooler counter flange DN 50 / ANSI 2" raw water outlet counter flange DN 50 / ANSI 2" raw water inlet counter flange DN 50 / ANSI 2"
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5.9.3.2 WCU open to atmospheric pressure Cabinet layout
Cable duct
Water pumps Heat exchanger Ion exchanger vessel Swing frame
Figure 5-21 WCU open to atmospheric pressure
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Flow diagram
2 3
Drain hose 12
4 5
Drain hose Make-up water 12 ISO-R 1/2
6
Drain hose 12
Figure 5-22 Flow diagram of WCU with open circuit
1 2 3 4
thread ISO-Rp 1/2 from converter pipe DN 80 from EXU hose nipple 26.5 thread ISO-Rp 1/2
5 6 7 8
to EXU hose nipple 26.5 to converter pipe DN 80 raw water outlet counter flange DN 80 / ANSI 3" raw water inlet counter flange DN 80 / ANSI 3"

The 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.
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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 control

Control 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 conductivity 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.
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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 connection

The 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 data

See 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 WCU

Refer to Chapter 10 - Options, 10.2 Options for WCU.
5.9.9 Air-to-air heat exchangers

Converters 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).
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Figure 5-23 Roof heat exchangers
5.10 Customer interface unit (CIU)

5.10.1 Overview
The 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 singlemotor drives are integrated into the customer interface unit (CIW) inside the WCU.
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Figure 5-24 CIU, typical cabinet layout

The CIU consists of the following main components: CIU1 CIU2, CIU3 CIUe Five additional I/O modules (S800 modules) with predefined I/Os for auxiliaries of each motor Predefined I/Os for transformer auxiliaries 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) Customer specific I/O configuration
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5.11 Input filter unit (IFU)

5.11.1 Overview
The 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 transformer 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.
Filter resistors
Filter capacitors
Figure 5-25 IFU cabinet layout

The IFU consists of the following main components: Decoupling reactors in the main circuit Filter reactors Filter capacitors Damping resistors
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TEU
L 1 TEU L 2 TEU L 3 TEU
IFU
ARU
L 1 ARU L 2 ARU L 3 ARU
Figure 5-26 IFU circuit diagram
5.12 Voltage limiter unit (VLU)

5.12.1 Overview
The 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.
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Air-cooled resistors
IGCTs
Figure 5-27 VLU cabinet layout

The 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.
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VLU
DC (+) VLSCD board
DC (NP)
VLSCD board DC (-)
INU
INTBoard
Figure 5-28 VLU circuit diagram
5.13 Resistor braking unit (RBU)

5.13.1 Overview
The 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.
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IGCTs
Water-cooled resistor
Figure 5-29 RBU cabinet layout

The 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.
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RBU
DC (+) VLSCD board
DC (NP)
VLSCD board DC (-)
INU
INTboard
Figure 5-30 RBU circuit diagram
5.14 Braking chopper unit (BCU)

5.14.1 Overview
An 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 termination 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.

The 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.
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DC (+) VLSCD board

BCU
External braking resistors
1
DC (NP)
2
VLSCD board DC (-)
INU
INTboard
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)
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Chapter 6 - Control system and process interfaces
6.1 Overview
This 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 customers disposition. Furthermore, the available control options are explained as well. Links to other documents Summary of references to linked documents in this chapter: Standard and Optional I/O Configuration (3BHS123187 ZAB E01)
6.2
Hardware and structure of the control system

The 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 controlhardware 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 ABBs 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.
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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. 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.
INTerface boards
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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 examples

In 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 with ARU 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.
COU AMC AMC
INT
INT ARU INU
INT
Figure 6-1
Single-motor drive with ARU
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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.
COU
PC tool Process I/O
Rectifier control
Process control system Control panel Fieldbus adapter ABB advant control RS 485
Inverter control
Process control system
PC tool
Control panel ABB advant control RS 485 Rotor speed
Fieldbus adapter
AMC
AMC
NTAC GRB
Rotor position
VA...VC
SYN
INT
ARU
INT
FT-link
INU
INT
CCB PAI
VNP to ground
EXU
MUB MUI
HVD + CVMI
V to ground VDC+ NP VDC-
HVD + CVMI
VDC-
GDR
Excitation supply
IA...IC
IA...IC
IDC
vDC
Figure 6-2
Single-motor drive with ARU (example with water-cooled EXU)
Single-motor drives with 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 singlemotor drive with a LSU is interconnected.
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VDC+
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COU
Inverter control
PC tool
Process control system ABB advant control
Control panel
Fieldbus adapter
S800
Process I/O
AMC
Rotor speed (optional) NTAC
LSU
FT-link
INU
INT
PPCS FSCD FSCD VDCDiode monitoring VNP to ground PPCS IOC IA...IC
PINT
HVD + CVMI
EAF
VDC+
IM
PG (optional) To NTAC (optional)
Figure 6-3 Multi-motor drive with ARU
Single-motor drive with LSU
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.
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COU2 AMC AMC
COU1 AMC
INT
INT ARU INU1
INT INU2
INT
Figure 6-4 Multi-motor drive with double ARU
Multi-motor drive with 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.
COU1 AMC AMC COU2 AMC
INT
INT ARU1
INT ARU2 INU1
INT INU2
INT
Figure 6-5 Single-motor drive with double ARU and double INU
Multi-motor drive with double ARU
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.
COU AMC AMC
INT
INT
INT ARU1
INT ARU2 INU1
INT INU2
INT
Figure 6-6
Single-motor drive with double ARU and double INU
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6.3 Local control devices
6.3.1 CDP local control panel

The 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.
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Alphanumeric display (4 lines x 20 characters)
Mode selection buttons
Selection and changing buttons Reset button Local, remote button Forward, reverse buttons
Enter button Setpoint setting button Start button Stop button
Figure 6-7
CDP control panel
6.3.2 CDP control panels, control switches and indicator lamps

CDP 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.
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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.
Control Panel - displays ARU status messages - displays ARU alarm and fault ..messages - resets alarm and fault messages
Figure 6-8
ARU control panel
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Control panel - starts and stops the motor - displays status messages of the converter - 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
Emergency off switch - prevents starting when actuated at standstill - main circuit breaker opens and DC link discharges when actuated during operation
Figure 6-9
INU control panel
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Control panel - starts and stops the motor - displays status messages of the converter - displays alarm and fault messages - resets alarm and fault messages
Alarm / fault lamp - ALARM: flashing light - FAULT: permanent light
Emergency off switch - prevents starting when actuated at standstill - main circuit breaker opens and DC link discharges when actuated during operation Figure 6-10 Control panel on additional control units
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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 Grounding switch, grounds the converter
Figure 6-11 Grounding switch on CBU
6.4
Fieldbus interfaces
6.4.1 Fieldbus types

Fieldbus 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 AF 100 fieldbus communication interface Profibus DP Modbus Modbus+ Ethernet DDCS Drive Bus
Fieldbus adapters
Adapter typea ABB FCI NPBA-12 NMBA-01 NMBA-01 NETA-01 CI858 (external adapter)
a. Other fieldbus adapters are available on request
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.
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6.4.2 Signals
Communication 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.
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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
Target Value Description
Input types Word Word Bit 0
INU INU INU/ ARU INU/ ARU INU/ ARU INU 1 0 1 0 1 0 1 0
Reference 1, speed reference in rpm Reference 2, torque reference Command to close MCB Command to open MCB Emergency OFF command (coast stop + MCB off) Emergency STOP command (emergency stop ramp) Command for state "Ready Reference" Normal stop (current controller is blocked) Normal operation Ramp generator output is set to zero (torque stop) Enable speed ramp Speed ramp is stopped, actual setpoint is frozen Enable setpoint Ramp generator input is set to zero (ramp stop) Fault reset (rising edge) Accelerate to inching speed reference 1 Stop inching (brake as fast as possible) Accelerate to inching speed reference 2 Stop inching (brake as fast as possible) AC 80 / AC 800 controller requests to control the drive No control from remote Select external control location 2 Select external control location 1 Process stop requested
Bit 1
Bit 2
Bit 3
Bit 4
INU
1 0
Bit 5
INU
1 0
Bit 6
INU
1 0
Bit 7
INU/ ARU INU
1 0 1 0
Bit 8
Bit 9
INU
1 0
Bit 10
1 0
Bit 11
1 0
Bit 12
1 0
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Table 6-3
Basic data exchange between AMC and process control: analog and binary outputs
Target Value Description
Output type Word Word Bit 0
INU INU INU/ ARU INU/ ARU INU/ ARU INU/ ARU INU/ ARU INU 1 0 1 0 1 0 1 0 1 0 1 0
Actual speed in rpm (integer: 20000= max. speed). Used by the speed controller Actual torque (integer: 10000= nominal torque) Drive ready for ON command (ready to close MCB) Not ready Drive ready for RUN command Not ready Drive ready for reference value Operation inhibited Drive tripped No fault Emergency OFF active (coast stop + MCB off) Emergency STOP active (emergency stop ramp) Switching ON is inhibited Alarm or warning is active Setpoint and actual value within margins Actual value differs from setpoint Drive controlled by overriding control system Drive controlled via CDP panel or DriveWindow Actual speed equals or exceeds limits Actual speed within limits External control location 2 selected External control location 1 selected
Bit 1
Bit 2
Bit 3
Bit 4
Bit 5
Bit 6
INU/ ARU INU/ ARU INU/ ARU INU/ ARU INU/ ARU INU/ ARU
1 0 1 0 1 0 1 0 1 0 1 0
Bit 7
Bit 8
Bit 9
Bit 10
Bit 11
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6.5
Hardwired process I/Os
6.5.1 Standard S800 I/O modules

Internal 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 configuration of the ACS 6000.
TB 820 bus modem Digital input module Digital output module
TU 830 termination unit
TU 831 termination unit
Figure 6-12 S800 I/O station Table 6-4 S800 I/O modules
No. of channels 16 16 16 8 relays 8 4 8 8 4 I/O rating 24 VDC 48 VDC (on request only) 24 VDC 230 VAC 0(4)...20 mA, 0(2)...10 V, 0(4)...20 mA, 0(2)...10V, +/- 20 mA, +/- 10 V PT100 resistance measurement 0(4)...20 mA, 0(2)...10 V, 0(4)...20 mA, 0(2)...10V, +/- 20 mA, +/- 10 V
I/O module type DI 810 DI 811 DO 810 DO 820 AI 810 AI 820 AI 830 AO 810 AO 820
Digital input Digital output
Analog input
Analog output
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TB 820 bus modem
Communication between an AMC controller and I/O modules is accomplished 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. standard AMC controller
CH 7
standard
option CIW1
DDCS S800 module bus TB 820 S800 module bus DI 810 DO 810 DI 810 TB 820 DI 810 DO 820 AI 820 TB 820 AI 820 DI 810 AO 820 DO 820 AI 820 COU1 WCU S800 module bus
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DO 820
Figure 6-13 S800 I/O configuration of an ACS 6000 single drive
6.5.2 Customer control signals

The 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 transformer 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.
ABB
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 users needs.
The resulting optional signals are listed in section Chapter 10 - Options, 10.5 Optional customer interfaces.
Fieldbus (e.g. Profibus) Fieldbus (e.g. Modbus) Service tool (*)
e.g. DriveWindow
ARU CBU /LSU)
INU
TEU /COU
WCU
Fieldbus adapters (*)
Control panel
CIW1 (option) S800(*)
AMC processor
Position / speed encoder (*)
S800
S800
Standard I/O (*) optional equipment Inverter/MCB/ Emergency off/ charging WCU monitoring Customer I /O (*)
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.
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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.
Fieldbus (e.g. Profibus) Fieldbus (Modbus)
Service tool (*) e.g. DriveWindow
Programming tool (*)
CDP control panel
CDP control panel
CDP control panel
AMC processor
AMC processor
AMC processor
Position/ speed encoder
Inverter 1 / MCB Emergency off / Charging
WCU monitoring
Customer I / O (*) CIU2
Inverter 2 I/O
Inverter 3 I/O
(*): optional equipment
Figure 6-15 Typical ACS 6000 multi-motor drive with option CIU2
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6.6
Control software
6.6.1 Control software structure

The 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
INU control
AMC AMCOS (AMC Operating System) Function block library Motor control + Fixed application Speed controller
Fieldbus adapter Advant AC controller S800 process I/O Control panel Panel application FCB application program
Direct torque controller
Modulator interface Magnetization reference to EXU
AMC table
AMC AMCOS (AMC Operating System) Function block library Fieldbus adapter Advant AC controller Control panel FCB application program DC voltage and cos controller Rectifier control + Fixed application
ARU control
Panel application
Modulator interface
AMC table
Figure 6-16 Software block diagram of the AMC controller
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6.6.2 Operating system
The 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 software

The 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 software

The 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 registered 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
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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 software

The 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 options
See Chapter 10 - Options for information.
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Chapter 7 - Engineering information
7.1 General
This 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: Links to other documents Summary of references to linked documents in this chapter: Appendix - Technical data 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 transformer and shall comply with IEC Publication 56 and ANSI c37.09.
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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 transformer
The ACS 6000 converter is fed from a main transformer providing sufficient 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 ARU

Refer also to Main Transformer Specification (3BHS125092 ZAB E01).
7.3.2 Main transformer for LSU

Refer also to Technical Requirement Specification (12-pulse LSU for single drives) (3BHS121185 ZAB E01) and Technical Requirement Specification (24-pulse LSU) (3BHS121186 ZAB E01).
7.4
ARU synchronization transformer

Refer also to Selection of Synchronization Transformers for ACS 6000 (3BHS125393 ZAB E01).
7.5
Asynchronous motor requirements

Asynchronous 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 requirements

Synchronous 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).
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7.7 Excitation supply
The 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 transformer 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. Excitation supply Excitation supply
Option A:
Option B:
EXU
EXU
EXU
EXU
EXU
EXU
Figure 7-1
Excitation transformer schemes for multi-motor drives
7.8
Selection of power cables
7.8.1 Power cable dimensioning

The 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.
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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 General cable type
Twisted pair(s) - overall shield Twisted pair(s) - overall shield Twisted pair(s) - overall shield Twisted pair(s) - overall shield Twisted pair cable with separately shielded pairs and overall shield Twisted pair cable with separately shielded pairs and overall shield
Signal type
Analog input Analog input Digital input Digital output Speed encoder Position encoder
Cross-section
0.5 to 2.5 mm2 / AWG 20 to AWG 12 0.5 to 2.5 mm2 / AWG 20 to AWG 12 0.5 to 2.5 mm2 / AWG 20 to AWG 12 0.5 to 2.5 mm2 / AWG 20 to AWG 12 0.5 mm2 4 x (2+1) 0.5 mm2 4 x (2+1)
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. Refer also to Wiring and Busbar Specification (3BHS205465 ZAB E01).
Cable marking
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Chapter 8 - Installation guidelines
8.1 General
This chapter provides all necessary instructions for transportation, requirements for the installation site as well as for the mechanical and electrical installation material. Links to other documents Summary of references to linked documents in this chapter: Appendix - Technical data ACS 6000 Outline Drawings Roxtec Cabinet Seals
8.2
Ambient conditions
Ambient conditions may require to derate the drive due to the presence of increased air temperature, cooling water temperature or altitude. Sufficient 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
Transport
Transport 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.
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30
Protect edges !
Figure 8-1
Cabinets with base frame and without door handles
30
Figure 8-2
Cabinets with base frame and marine-type door handles

Cable angle indicated on cabinet roof
MAX.
120
Figure 8-3
Cabinets without base frame
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8.4 Installation site requirements
Foundation and floor levelling
Cabinets must be installed in upright position. The floor must be of non-flammable material, with a smooth and nonabrasive surface, protected against humidity diffusion, levelled and able to support the weight of the converter (min. 1000 kg/m2). 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. 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.
Dimensions
Clearances
Recommended 400 mm or more
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.
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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. 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).
Safety aspects
8.5
Raw water flanges

The 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.
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DN 65
ANSI B16.5 150 lbs 2.5
Dimensions are in mm (in) Figure 8-5 Flanges
8.6
Power cable installation, grounding and shielding

This chapter describes the minimal requirements for power cable installation, grounding and shielding. Additional requirements in local regulations have to be considered.
8.6.1 Sealing system for power cable entry

The 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.
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Sealing module
Removable layers to adapt the sealing module to the cable diameter Conductive foil
Frame
Compression wedge
Sealing module
Figure 8-6
Power cable entry with roxtec sealing system
8.6.2 Connecting ARU to supply transformer

Figure 8-7 shows an installation with 3 cables running in parallel. The total cable diameter is defined by the power consumption of the drive.
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Feeding transformer or busbar
Feeding transformer or busbar
16 mm2< A < 50 mm2 (Cu)
Armor Shield
16 mm2< A < 50 mm2 (Cu)
TEU ACS 6000 ARU
TEU ACS 6000 ARU
a) with 3-core cables
b) with single-core cables
Figure 8-7
ARU side cabling
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8.6.3 Connecting LSU to supply transformer
Feeding transformer
Equipotential bonding
Shield
Armor
16 mm2< A < 50 mm2 (Cu)
TEU ACS 6000 LSU
Figure 8-8
LSU side cabling
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8.6.4 Connecting motor to INU
ACS 6000 INU
TEU
ACS 6000 INU

TEU
Equipotential bonding
Armor
16 mm2< A < 50 mm2 (Cu) 16 mm2< A < 50 mm2
Shield
(Cu)
Motor
Motor
a) with 3-core cables Figure 8-9
b) with single-core cables INU side cabling
8.7
Equipment grounding
The 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.
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Protective Earth (PE) to be connected to system ground
Figure 8-10 TEU, connection to system ground
8.8
Installation of auxiliary power and control cables

The cable entry for auxiliary and control cables is prepared for the use of the Roxtec sealing system.
a c e
b d f
Sealing inserts
CS F 16 frame
Figure 8-11 Control cable entry with roxtec sealing system
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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.
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Chapter 9 - Ordering information
9.1 General
Ths chapter provides assistance in selecting the appropriate drive and the included options. Links to other documents Summary of references to linked documents in this chapter: Appendix - Technical data ACS 6000 Type code (3BHS128455 ZAB E01)
9.2
Drive selection
9.2.1 Required application data

ABB 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 customers 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 procedure

The converter is configured according to the following steps: 1. 2. 3. 4. Select type of configuration (single-motor drive, multi-motor drive, redundant or twin configuration). Select field of application. Indicate number of motors. Select the appropriate inverter configuration for each motor based on the main data.
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Select the type of rectifier (ARU or LSU) based on process needs and braking capability requirements. Add a RBU or BCU to an ACS 6000 with LSU if emergency braking capabilities are required. Select options if needed. The available options are listed in Chapter 10 - Options.
5. 6. 7.
9.2.3 Configuration rules

The 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 code
See ACS 6000 Type code (3BHS128455 ZAB E01)
9.4
Option list
See Chapter 10 - Options.
9.5
External system data

See Chapter 7 - Engineering information.
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9.6 Technical data
See Appendix - Technical data.
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Chapter 10 - Options
10.1 Converter hardware
Process 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)
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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 Insulation monitoring device for medium voltage circuit Pulse encoder interface (NTAC board) for rotor speed measurement Fast I/Os (NBIO-21) 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) Nickel-coated busbars Varnished circuit boards
Instrumentation
Ambient conditions
Enhanced corrosion protection
10.2 Options for WCU

The 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)
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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 temperature 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 configurations. 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
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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 touchscreen 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.
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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.
DriveMonitorTM Embedded PC Figure 10-4 ACS 6000 with DriveMonitorTM installed in a console
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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 interfaces

The 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 users 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 controller

The 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.
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AMC controller
CH 7
CH 4
DDCS
DDCS S800 Module Bus TB 820 S800 Module Bus DI 810 DO 810 DI 810 TB 820 DI 810 DO 820 AI 820
AC 80 / AC 800 Controller
AI 820 DI 810 AO 820 DO 820 AI 820
DO 820
COU1
WCU
CIW2 / CIW3
Figure 10-5 S800 I/O configuration with AC 80 / AC 800
10.6 Marine version

The 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 vibrations being conveyed to the converter. Horizontal door handles
Marine-type door handles Damping mat between base frame and converter cabinets Figure 10-6 Marine version
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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.
45
45 90
Roof-side steel bracket Wall-side steel bracket Sleeve Rubber pad
Assembled roof attachment
Ceiling fastening
Wall fastening
Figure 10-8 Roof fixings
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Connecting pieces at the front and at the back
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
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10.10 Documentation
Paper copies of the users manual (users manual on CD-ROM is standard)
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Index
A
Active Rectifier Unit ARU Application Control 74 42 mine hoist Motor Control Functions Motor Requirements Multi machine drive multiple units 35 41 126 25 25
B
basic configuration Bus Bars 23 64
O
Operating System Oscillation Damping overland conveyors 123 41 36
C
Cabinet Design Control Features (DTC) Control System Crowbar Thyristors 62 41 103 72, 74
P
power range Protection Functions 15 49
D
di/dt choke Direct Torque control, methods drilling rig 72, 74 39 27
R
Rolling Mill Applications Rougher mill 30 32
F
Four-quadrant operation 20
S
sendzimir mill single machine configuration Single machine drives Speed Control 34 17 24 41
G
Grounding 64
T
Torque Control 41
I
Inverter Unit INU 78
V
Voltage Limiting Unit 97, 99, 101
L
Line Supply Unit Load Share Control 70 42
M
Main Circuit Breaker Main circuit breaker, selection Main State Machine 42 125 124
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ABB Switzerland Ltd Medium Voltage Drives CH-5300 Turgi / Switzerland Tel +41 58 589 27 95 Fax +41 58 589 29 84 Email mvdrives@ch.abb.com www.abb.com/motors&drives 3BHS123322 ZAB E01 Rev. D 18-09-2009
ABB Switzerland Ltd reserves all rights to this document. Unauthorised duplication is not permitted.
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Appendix A -Technical data
Converter output / Motor connection
Table A-1 Output voltage and current ratings
Type ACx ... _1y7 ACx ... _1y9 ACx ... _2y7 ACx ... _2y9 Rated output voltage with ARU 3150 ... 3300 V 3150 ... 3300 V 2 x 3150 ... 3300 V 2 x 3150 ... 3300 V Rated output voltage with LSU with 2 x 1725 V input voltage 3000 ... 3100 V 3000 ... 3100 V 2 x 3000 ... 3100 V 2 x 3000 ... 3100 V Rated output voltage with LSU with 2 x 1650 V input voltage 3000 V 3000 V 2 x 3000 V 2 x 3000 V Rated output current 1300 A 1670 A 2 x 1300 A 2 x 1670 A
"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 frequency range Minimal base frequency Maximum field weakening range Maximum motor cable length Efficiency Static speed inaccuracy Dynamic speed inaccuracy Air gap torque ripple components
0...75 Hz 3.1 Hz 1:5 300 m (984 ft), longer on request Depends on individual configuration With encoder: within +/- 0.01% Without encoder: within +/- 0.1% With encoder: within 0.2 ... 0.5% s Without encoder: within 0.5 ... 1% s < 1% (Motor fn <25 Hz, frequency components below 100 Hz) < 2% (Motor fn <50 Hz, frequency components below 100 Hz) < 3% (Motor fn <60 Hz, frequency components below 100 Hz)
Power factor for synchronous motors Power factor for asynchronous motors
Controlled to 1.0 Depends on motor characteristics
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Appendix A - Technical data
ABB
ACS 6000 with Active Rectifier Unit (ARU)

Table A-2 Input voltage and current ratings
Type ACx 6107_A06_... Input voltage 1 x 3160 V, +10/-10% 1 x 3000 V, +15/-5% ACx 6109_A06_... 1 x 3160 V, +10/-10% 1 x 3000 V, +15/-5% ACx 6109_F06_... 1 x 3160 V, +10/-10% 1 x 3000 V, +15/-5% ACx 6207_A12_... 2 x 3160 V, +10/-10% 2 x 3000 V, +15/-5% ACx 6209_A12_... 2 x 3160 V, +10/-10% 2 x 3000 V, +15/-5% ACx 6309_A18_... 3 x 3160 V, +10/-10% 3 x 3000 V, +15/-5% Rated input current 1 x 1300 A 1 x 1300 A 1 x 1670 A 1 x 1670 A 1 x 1300 A 1 x 1300 A 2 x 1380 A 2 x 1380 A 2 x 1670 A 2 x 1670 A 3 x 1670 A 3 x 1670 A Pulses 6-pulse 6-pulse 6-pulse 6-pulse 6-pulse 6-pulse 12-pulse 12-pulse 12-pulse 12-pulse 18-pulse 18-pulse EMC filter (IFU) No No No No Yes Yes No No No No No No
"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 Phase shift
Safe operation with reduced output power is possible down to -20% for 3160 V input voltage. Phase shift between transformer secondary windings: 30 for 12-pulse ARUs 20 for 18-pulse ARUs
Input frequencies Voltage unbalance Fundamental power factor cos
50 / 60 Hz 5% max. 2% (Uneg / Upos according to IEC 61000-2-4) Controlled to cos = 1.0 Optionally, cos can be controlled in a range of 0.8 (leading) ... 0.8 (lagging). (MVA ratings remain the same as for cos = 1.0)
Maximum cable length Control principle
300 m (984 ft) Vector control with optimized pulse patterns
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ACS 6000 with Line Supply Unit (LSU)
Table A-3 Input voltage and current ratings
Type ACx 6107_D06_... ACx 6107_L12_... Input voltage 1 x 3300 VAC, +10/-10% 1 x 2 x 1725 VAC, +10/-10% 1 x 2 x 1650 VAC, +15/-5% ACx 6109_L12_... 1 x 2 x 1725 VAC, +10/-10% 1 x 2 x 1650 VAC, +15/-5% ACx 6114_L12_... 1 x 2 x 1725 VAC, +10/-10% 1 x 2 x 1650 VAC, +15/-5% ACx 6207_L24_... 2 x 2 x 1725 VAC, +10/-10% 2 x 2 x 1650 VAC, +15/-5% ACx 6209_L24_... 2 x 2 x 1725 VAC, +10/-10% 2 x 2 x 1650 VAC, +15/-5% ACx 6214_L24_... 2 x 2 x 1725 VAC, +10/-10% 2 x 2 x 1650 VAC, +15/-5%
Rated input current 1 x 1300 A 1 x 2 x 1300 A 1 x 2 x 1300 A 1 x 2 x 1670 A 1 x 2 x 1670 A 1 x 2 x 2600 A 1 x 2 x 2600 A 2 x 2 x 1300 A 2 x 2 x 1300 A 2 x 2 x 1670 A 2 x 2 x 1670 A 2 x 2 x 2600 A 2 x 2 x 2600 A
pulses 6-pulse 12-pulse 12-pulse 12-pulse 12-pulse 12-pulse 12-pulse 24-pulse 24-pulse 24-pulse 24-pulse 24-pulse 24-pulse
"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 Voltage unbalance Fundamental power factor Maximum cable length
50 / 60 Hz 2% max. 2% (Uneg / Upos according to IEC 61000-2-4) cos > 0.95 300 m (984 ft)
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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 supply
Auxiliary voltage
Auxiliary voltage frequency Uninterruptible power supply
50 / 60 Hz, +/-2% 110 VDC 220 VDC 110 VAC, 1-phase 230 VAC, 1-phase
EXU supply
Auxiliary voltage Auxiliary voltage frequency 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
50 / 60 Hz, +/-2%
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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'.
Parameter 1K4 Climatic conditions Air temperature Relative humidity Absolute humidity 1Z3 Special Climatic Conditions Movement of surround. air 1B1 Biological conditions Flora Fauna 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) 10 m/s2 - (9...200 Hz) Marine application1: 7 m/s2 (23 ft/s2) - (13.2...100 Hz) negligible negligible 30 m/s (98 ft/s) -25... +55 C (-13 F... 131F) 5...100 % 0.5...29 % Limits
acceleration amplitude
1 Requirement of classification societies: American Bureau of Shipping, Bureau Veritas, Det Norske Veritas, Germanischer Lloyd, Lloyds register
Storage time
Up to one year in the original packaging
Transportation
Transportation conditions The transportation conditions are based on IEC 60721-3-2 'Classification of groups of environmental parameters and their severities; Transportation'
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ABB
.
Parameter 2K4 Climatic conditions Low air temperature High air temperature: unventilated enclosures ventilated enclosures/outdoor Relative humidity Absolute humidity 2B1 Biological conditions Flora Fauna 2M1 Mechanical conditions Stationary vibration sinosoidal: displacement amplitude acceleration amplitude no no 70 C (158 F) 40 C (104 F) 95 % 60 % -40 C (-40 F)
Limits
3.5 mm (0.14 in) - (2...9 Hz) 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 Free fall Toppling Rolling, pitching2: degree period Steady-state acceleration no no 20 m/s2 (66 ft/s2) 100 m/s2 (328 ft/s2) 0.1 m (0.33 ft) - (mass > 100 kg [220 lb]) no (mass > 100 kg [220 lb])
1 Requirement of classification societies: American Bureau of Shipping, Bureau Veritas, Det Norske Veritas, Germanischer Lloyd, Lloyds register 2 An angle of 35 (pitching) can only occur temporarily, angles up to 22.5 (rolling) can occur for long periods of time.
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Max. transport time Two months
Operation
Operation conditions Operation conditions are according to IEC 721-3-3 Stationary use at weather-protected locations.
Parameter 3K3 Climatic conditions 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) 5...85 % 1...25 g/m3 (0.036 lb/in3) no Limits
Relative humidity Absolute humidity Condensation 3B1 Biological conditions Flora Fauna 3C2 Chemically active substances Sea salt and road salts Sulphur dioxide Hydrogen sulphide Chlorine Hydrogen chloride Hydrogen fluoride Ammonia Ozone Nitrogen oxides 3S2 Mechanically active substances Sand Dust (suspension)
no no
Salt mist 0.3...1.0 mg/m3 (1.084x10-11... 3.613 x10-11lb/in3) 0.1...0.5 mg/m3 (3.613x10-12... 1.806x10-11lb/in3) 0.1...0.3 mg/m3 (3.613x10-12... 1.0838x10-11lb/in3) 0.1...0.5 mg/m3 (3.613x10-12... 1.806x10-11lb/in3) 0.01...0.03 mg/m3 (3.613x10-13...1.0834x10-12lb/in3) 1...3 mg/m3 (3.613x10-11...1.084x10-10) 0.05...0.1 mg/m3 (1.806x10-12...3.613x10-12) 0.5...1.0 mg/m3 (1.806x10-1...3.613 x10-11lb/in3)
30 mg/m3 (1.084x10-9) 0.2 mg/m3 (7.225x10-12)
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Parameter Dust (sedimentation) 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) 5 m/s2 (16.4 ft/s2) - (9...200 Hz) Marine application**: 7 m/s2 (23 ft/s2) - (13.2...100 Hz) Limits 1.5 mg/m3 (5.419x10-11)
acceleration amplitude
Non-stationary vibration (incl. shock): shock response spectrum 40 m/s2 (131.2 ft/s2)
* Lower temperatures are permitted, as long as it is guaranteed that the cooling 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, Lloyds register
Rotation around Xaxes (Rolling) Installation altitude
Up to 22.5 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)
Frostproofing
Lowest permitted freezing point: -25C (-13F) Permitted anti-freeze: pure monoethylene glycol Water glycol concentration for the desired frostproofing:
C 0 -10 -20 -30 -40 -50 -60 0 10 20 30 40 50 60 70 80 90 100 % volume
Frost proofing - 10 C (14 F) - 20 C (-4 F) - 30 C (-22 F) - 40 C (-40 F) Glycol 20 % 34 % 44 % 52 % Distilled Water 80 % 66 % 56 % 48 %
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Cooling
Cooling method Raw water quality Water-cooled closed loop system
Raw water of good quality is essentially industrial waterand must meet the following requirements:
Parameter pH Specific conductivity Hardness Chloride (Cl) Total dissolved salt Undissolved particles Total M-alkalinity (TAC) 79 < 500 S/cm 3 15 dH < 300 mg/l < 1000 mg/l < 1000 mg/l 0 300 mg CaCO3/l Value
Raw water connection requirements

Raw water connection Flow rate Pressure drop Design pressure Test Pressure Raw water pressure Inlet temperature** 250 - 870 l/min* 70 - 160 KPa* (0.7 -1.6 bar)* 1000 KPa* (10 bar)* 1500 KPa* (15 bar)* 20 - 50 KPa (0.2 - 0.5 bar) 5 - 32 C* (41 Optional: up to 100 kPa (1 bar) Operation with rated power Marine applications Output current is derated by 1.5%/degree Remarks Depending on required cooling capacity Depending on drive size and application
- 90 F)
5 - 36 C* (41 - 97 F) Extended temperature Outlet temperature** 32 - 42 C* (90 - 108 F) 5 - 37 C* (41 5 - 42 C* (41
- 99 F) - 108 F)
Marine applications
* 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.
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The internal main cooling circuit of the converter is operated with deionized water as specified below:
Parameter pH Specific conductivity Hardness Chloride (Cl) Copper (Cu) Total dissolved salt Undissolved particles Value 7 8.5 < 300 S/cm 3 10 dH < 300 mg/l < 0.1 mg/l < 1000 mg/l < 5 mg/l
Internal cooling circuit
Drinking water of good quality generally meets the requirements for makeup 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 to environment Approx. 6% of the losses
Converter enclosure
Standard enclosure class Cabinet color IP32
RAL 7035 "light gray"
Filter mesh
Door filter mats in converters with IP 54 are specified for filter particles with a size > 10 m.
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 (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
Antifreeze
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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] Dielectric withstand voltage Electromagnetic compatibility 30 kV according to IEC / EN 60071-1 10 kV According to IEC / EN 61000-4-2: Contact discharge: Air discharge: Aux-supply power-ports: Signal-ports: 6 kV 8 kV 2 kV, 5 kHz 1 kV, 5 kHz
According to IEC / EN 61000-4-4:
According to IEC / EN 61000-4-5: Aux-supply power-ports line-to-earth: 2 kV Aux-supply power-ports line-to-line: Signal-ports: 1 kV 1 kV
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ACS 6000 - Applicable Codes and Standards
.
International Standards for Design and Construction

IEC / EN 60071-1 IEC / EN 60146-1-1 IEC / EN 60529 IEC / EN 60664-1 IEC 62103 (EN 50178) IEC / EN 61800-4 Insulation coordination - Part 1: Definitions, principles and rules Semiconductor convertors - General requirements and line commutated convertors - Part 1-1: Specifications of basic requirements Degrees for protection provided by enclosures (IP-Code) Insulation coordination for equipment within low-voltage systems - Part 1: Principles, requirements and tests Electronic equipment for use in power installations Adjustable speed electrical power drive systems - Part 4: General requirements - 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 - Electromagnetic disturbance characteristics - Limits and methods of measurement Electromagnetic compatibility (EMC) - Part 4-2: Testing and measurement techniques - Electrostatic discharge immunity test Electromagnetic compatibility (EMC) - Part 4-3: Testing and measurement techniques - Radiated, radio-frequency, electromagnetic field immunity test Electromagnetic compatibility (EMC) - Part 4-4: Testing and measurement techniques - Electrical fast transient/burst immunity test Electromagnetic compatibility (EMC) - Part 4-5: Testing and measurement techniques - Surge immunity test Electromagnetic compatibility (EMC) - Part 4-6: Testing and measurement techniques - Immunity to conducted disturbances, induced by radiofrequency fields Electromagnetic compatibility (EMC) - Part 6-2: Generic standards Immunity for industrial environments Electromagnetic compatibility (EMC) - Part 6-4: Generic standards - Emission standard for industrial environments
IEC / EN 61000-4-2 IEC / EN 61000-4-3
IEC / EN 61000-4-4 IEC / EN 61000-4-5 IEC / EN 61000-4-6
IEC / EN 61000-6-2 IEC / EN 61000-6-4
3BHS125313 ZAB E01 Rev. B
1 (2)
ABB
IEC / EN 61800-3 Adjustable speed electrical power drive systems - Part 3: EMC requirements 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 Classification of environmental conditions Part 3: Classification of groups of environmental parameters and their severities Section 2: Transport Classification of environmental conditions Part 3: Classification of groups of environmental parameters and their severities Section 3: Stationary use at weatherprotected locations
IEC / EN 60721-3-2
IEC / EN 60721-3-3
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) Lloyds Register (LR)
2 (2)
3BHS125313 ZAB E01 Rev. B

ABB ACS 6000 Tech Catalog RevD

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Water-cooled ACS 6000

ACS 6000 Technical Catalog

3BHS123322 ZAB E01 Rev. D

3BHS123322 ZAB E01 Rev. D

ACS 6000 Technical Catalog

103 103 103 103 105 109 109

ACS 6000 Technical Catalog

3BHS123322 ZAB E01 Rev. D

3BHS123322 ZAB E01 Rev. D

ACS 6000 Technical Catalog

ACS 6000 Technical Catalog

3BHS123322 ZAB E01 Rev. D

3BHS123322 ZAB E01 Rev. D

ACS 6000 Technical Catalog

ACS 6000 Technical Catalog

3BHS123322 ZAB E01 Rev. D

3BHS123322 ZAB E01 Rev. D

ACS 6000 Technical Catalog

ACS 6000 Technical Catalog

3BHS123322 ZAB E01 Rev. D

3BHS123322 ZAB E01 Rev. D

ACS 6000 Technical Catalog

ACS 6000 Technical Catalog

3BHS123322 ZAB E01 Rev. D

3BHS123322 ZAB E01 Rev. D

ACS 6000 Technical Catalog

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

ACS 6000 Technical Catalog

3BHS123322 ZAB E01 Rev. D

3BHS123322 ZAB E01 Rev. D

ACS 6000 Technical Catalog

Single drive with diode rectifier

Multi-drive with active rectifier

Redundant drive with diode rectifier (planned solution)

Typical examples for basic configurations

Direct torque control

ACS 6000 Technical Catalog

3BHS123322 ZAB E01 Rev. D

Integrated gate commutated thyristor

Active rectifier unit

LSU Common DC bus

3BHS123322 ZAB E01 Rev. D

ACS 6000 Technical Catalog

Benefits for the customer

ACS 6000 Technical Catalog

3BHS123322 ZAB E01 Rev. D

Low maintenance cost

3BHS123322 ZAB E01 Rev. D

ACS 6000 Technical Catalog

ACS 6000 Technical Catalog

3BHS123322 ZAB E01 Rev. D

3BHS123322 ZAB E01 Rev. D

ACS 6000 Technical Catalog

The ACS 6000 drive types

2.2.1 Single-motor drives

ACS 6000 Technical Catalog

3BHS123322 ZAB E01 Rev. D

Chapter 2 - Types and applications

Mains Synchronization voltage Aux. power Excitation power

Single-motor drives, basic configurations

3BHS123322 ZAB E01 Rev. D

ACS 6000 Technical Catalog