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ACS 1000

Medium Voltage AC Drives for Speed and Torque Control


of 315– 5000kW Motors
2 - ACS 1000 ABB
Simplified Performance

Drawing from over a century of industrial Rugged Reliability


manufacturing experience, ABB provides a
simple, reliable approach to electronic power We know that reliability is of paramount
control: the ACS 1000 medium voltage drive importance. The low component count of
for speed and torque control of 315 – 5000kW the ACS 1000 makes it inherently more
asynchronous motors for voltages of 2.3, 3.3 reliable. Furthermore, we test each component
and 4.0kV. individually and load test every drive before
delivery.

Key Product Features Smooth System Integration


• Retrofit-ready
The ACS 1000 is retrofit-ready with a variety
for existing motors and suitable for
of flexible options you can choose according to
most medium voltage applications
your needs. Network harmonics and disturbances
including pumps, fans, compressors,
to existing electrical equipment are minimized.
extruders, conveyors
Standard motors can be used without any
derating or need for special motor insulation.
• Output sine filter
for pure sinusoidal voltage and current
High Levels of Performance
output: standard motors, no motor
derating, no voltage stress and no
The ACS 1000 delivers precise process control
common mode voltages on the motor
through ABB’s patented Direct Torque Control
insulation
(DTC) technology. DTC can provide the quickest
torque step response of any motor control
• IGCT power semiconductors
platform. This ensures the highest control
for highest reliability
accuracy without the use of an encoder, despite
input power variations or sudden load changes.
• Fuseless design
for reliable, non-aging, maintenance-
Comprehensive Service
free circuit protection.
We have the largest service organization
• DTC control platform for exceptionally
worldwide which backs every drive we
high torque and speed performance
deliver. From training to technical support,
we stand ready to provide you with a com-
prehensive program of service options.

Isolation Rectifier DC Link Inverter Filter Induction


transformer motor

The ACS 1000 drive’s three-level voltage source inverter topology with sine filter output

ABB ACS 1000 - 3


Smooth System Integration

Clean Integration into Existing Systems Retrofit-ready Simplicity

Due to its on-board macros and user-friendly The ACS 1000 is optimized for retrofits.
software tools, the ACS 1000 is probably the With its small footprint and input isolation
fastest commissioned medium voltage drive transformer flexibility the drive can fit where
in the world. you need it. Its enhanced motor identification
routine simplifies the start-up procedure by
ABB offers an open communication strategy determining all the key motor parameters
enabling connection to a PLC or a DCS system. automatically – simply enter the motor name
Fieldbus connectivity with a wide variety of plate data and the ACS 1000 does all the rest.
protocols is available. Thanks to the perfectly sinusoidal output
The ACS 1000 meets the IEEE 519-1992 and waveform existing asynchronous motors can
IEC 61000-2-4 specifications for voltage and be used without derating. The design also
current harmonic distortion for virtually all ensures that the motor is not subjected to
installations. This eliminates the need for harmful common mode voltages. This means
expensive harmonic filters and protects other special motor insulation is not required.
electrical equipment from harmonic distur-
bances.

The ACS 1000 meets EN (IEC), CE, UL, cUL


and other standards to ensure smooth system
integration worldwide.

ACS 1000 System Integration System Design Flexibility


• Retrofit-ready The ACS 1000 can be configured with either
• Sinusoidal output an integrated dry-type or separately installed
• Low network harmonics input isolation transformer. This flexibility
• High power factor enables the use of oil filled transformers when
• Small footprint the transformer will be mounted outdoors.
• Fast commissioning The advantage is that you are not forced to
• EMC compliant accept dissipated heat losses from the input
• Gentle on system components isolation transformer in the electrical room.

Output Sine Filter


• Ensures sinusoidal voltage and
current output on the motor side
Voltage • Provides compatibility with standard
Current
asynchronous motors
• Avoids need to derate motor
0 • Eliminates voltage stress and
common mode voltages to
the motor insulation
• Reduces motor noise
• Allows using existing
non-shielded cables

Output waveforms with the motor running at full speed. The ACS 1000 drive’s sine filter ensures a perfectly
sinusoidal voltage and current on the motor side.

4 - ACS 1000 ABB


IndustrialIT Benefits
• Easy integration of the drive into
ABB’s IndustrialIT means increased
customer industrial environment
standardization and seamless interaction
• All drive information readily available
of different ABB products.
in electronic form
The ACS 1000 has been certified to bear
• Drive communication with the
the IndustrialIT Enabled symbol, a special
environment through control panels,
mark indicating that the drive can be easily
standardized fieldbus adapters and
integrated into the IndustrialIT architecture
interfaces (OPC, OLE for Process
in a ‘plug & produce’ manner.
Control)
• Easy to use start-up and maintenance tools

Customer support systems Business systems for


for product training, help sourcing, ordering,
desk, service spare parts

Process
Controllers

Control
Network

Application
Controller

Fieldbus

Low Voltage Medium Voltage


AC Drive AC Drive

Electrical
machinery in
the process

Software for dimensioning, Software tools for energy


configuration, start-up, calculations, efficiency
monitoring, documents analysis, new drive selection

The Principle of Industrial IT

ABB ACS 1000 - 5


Streamlined Technology

The Medium Voltage Challenge GTO: Thyristor Standard

Until now, the power switches for medium GTO technology is reliable and conduction
voltage drives have been either Gate Turn Off losses at medium voltage levels are tolerable.
Thyristors (GTO) or Insulated Gate Bipolar The problem is that non-homogeneous
Transistors (IGBT). For medium voltage app- switching requires huge additional circuitry
lications, such devices force design trade-offs for turn off. Again, parts count increases
that increase the cost and complexity of power resulting in larger drives. Costs increase.
control systems. ABB is intimately familiar with Reliability decreases.
these trade-offs. We have invested in and further
developed these devices for many years. IGCT: Specifically Designed for
Medium Voltage
IGBT: Conventional Transistorized Approach
ABB is keenly aware of the need for a power-
Both low voltage and high voltage IGBTs switching device that displays:
have been used in medium voltage drives. • High-speed switching like an IGBT
IGBTs are fast switching but conduction losses • Low-loss conduction like a GTO
are high at medium voltage levels and com- • Reliability in a wide range of medium
plicated series connections of multiple IGBTs voltage applications
are required. High voltage IGBTs have fewer
series-connected devices relative to low voltage ABB has developed the simple solution based
IGBTs, but conduction losses are even higher. on proven technology: the Integrated Gate
Overall parts count increases resulting in bigger Commutated Thyristor (IGCT). This evolutionary
drives. Costs go up. Reliability goes down. technology consists of a redesigned GTO, which
incorporates significant design breakthroughs.
The new IGCT delivers fast, homogeneous
switching and inherently low losses.
The IGCT is used with Voltage Source Inverter
(VSI) topology which is intrinsically less
complex and more efficient compared
to other topologies. The IGCT-based
ACS 1000 meets the complex
medium voltage drive
challenge.

IGCT power semiconductors for highest reliability and performance

6 - ACS 1000 ABB


Streamlined Technology Requires
IG
Fewer Parts C
an T g
r
Depending on the voltage level, an IGCT- co d rel eatl
n v i a b y im
based medium voltage drive typically requires en
as little as one fifth the number of power tio ility prov
n a – e es
semiconductor devices as existing low voltage ls
IGBT solutions. IGCT’s lower losses mean o l u x t e n perf
less cooling equipment and higher inherent t i o d i n orm
ns g b an
reliability. Fewer parts. Higher reliability. . e y ce
Simple solution. on
d

Switching Technology Comparison – for Medium Voltage Applications

GTO LV IGBT HV IGBT IGCT


Switching Available for most Only available for Only available for Available for most
technology MV levels MV levels with series MV levels with series MV levels
connection connection

Low on-state losses Moderate on-state High on-state losses Low on-state losses
losses

High switching losses Low switching losses Moderate switching Low switching
losses losses

Low switching High switching High switching High switching


frequency frequency frequency frequency

Snubbers required Snubberless but Snubberless but Snubberless


requires synchronized requires synchronized
gate driver gate driver

Separate gate driver Compact gate driver Compact gate driver Integrated gate
driver

Power Safe from Additional protection Additional protection Safe from


circuitry catastrophic failure needed needed catastrophic failure

Moderate parts count High parts count Moderate parts count Low parts count

Equipment Moderately compact High parts count leads Moderately compact Very compact
design to reduced reliability
and large equipment
size

Moderate cabling and High cabling and Moderate cabling and Low cabling and
interconnection interconnection interconnection interconnection

ABB ACS 1000 - 7


The ACS 1000 Medium Voltage AC Drive
Air-cooled

Small footprint and no rear or side EMC compliant Electromechanically


access required for less floor cabinet for problem- interlocked doors of
space and increased retrofit free operation in power sections for
flexibility electro-magnetic safety
environment

Control section DC bus grounding Cooling air intake


• Same layout for air-cooled and switch for safety
water-cooled units
User-friendly control panel for
local operation
• Keypad with multi-language
display
• Main supply on/off pushbuttons
• Emergency stop pushbutton

8 - ACS 1000 ABB


Seperated connection
section for power cables
Top and bottom cable
entry/exit as standard
IGCT power
semiconductors for
Control electronics Integrated fan for highest reliability and
mounted on swing low noise level performance
frame for easy access

Application and motor


control board with fast
digital signal processor
and DTC
Fiber optics for noise 12-pulse input Output filter for
immunity and galvanic bridge as standard smooth sinusoidal
isolation 24-pulse input current and voltage
Standard and optional bridge as option, for waveform
I/O boards for greater stringent harmonic
functionality mitigation

Battery back-up for


electronic power supply
for maximum reliability

ABB ACS 1000 - 9


The ACS 1000 Medium Voltage AC Drive
Water-cooled

Small footprint for less floor space EMC compliant


and increased retrofit flexibility cabinet for problem-
free operation in
electro-magnetic
environment

Control section DC bus grounding Electromechanically


• Same layout for air-cooled and switch for safety interlocked doors of
water-cooled units power sections for
safety
User-friendly control panel for
local operation
• Keypad with multi-language
display
• Main supply on/off pushbuttons
• Emergency stop pushbutton

10 - ACS 1000 ABB


Seperated connection
section for power
cables Inverter stacks on IGCT power
Top and bottom Control electronics swing frame for easy semiconductors for
cable entry/exit as mounted on swing accessibility and highest reliability and
standard frame for easy access performance performance

Application and motor Output filter for 12-pulse input Water cooling cabinet
control board with fast smooth sinusoidal bridge as standard incorporating: main,
digital signal processor current and voltage 24-pulse input secondary and water
and DTC waveform bridge as option, for treatment sub-systems
stringent harmonic • Accessible during
Fiber optics for noise drive operation
mitigation
immunity and galvanic • Design allows for
isolation service without the
Standard and need to drain the
optional I/O boards for water circuit
greater functionality • Redundant pump
optional
Battery back-up for
electronic power supply
for maximum reliability

ABB ACS 1000 - 11


Performance

DTC Technology at the Heart of the ACS 1000

Direct Torque Control (DTC) is an optimized


motor control method for AC drives that allows
direct control of all the core motor variables.
This opens up AC drive capabilities never
before realized and offers benefits for all
applications.

What is Direct Torque Control?

In DTC, stator flux and torque are used as


primary control variables. The motor state
calculations are updated 40,000 times a
second (i.e. every 25 µs) in the advanced
motor software model by the high-speed
digital signal processor. Due to the continuous
updating of the motor state and the comparison
of the actual values to the reference values,
every single switching in the inverter is
determined separately.

Encorderless

Encoders are sensitive instruments in a


harsh process environment and are known
to be susceptible to failures. Due to DTC the Typical torque (T) response of a DTC drive, compared with flux
ACS 1000 can run the motor at nominal speed vector control and open loop pulse width modulation (PWM)
accuracy and under full performance without
any speed feedback.

Maximized Starting Torque Reduced Noise

Precise torque control provided by DTC Because of the separately determined switching,
allows the ACS 1000 to provide maximized the ACS 1000 has no fixed switching frequency.
starting torque that is both controllable and This eliminates resonances that cause irritating
smooth. noise associated with AC drives using conven-
tional PWM technology.
Fast Response to Mains Fluctuations and
Process Side Changes Highest Efficiency

The exceptionally fast torque step response The inherently total low losses of the IGCT
of the ACS 1000 means that it can respond switching devices are ideally complemented
to process and mains changes extremely fast. by the high economical performance of DTC,
This enables easy handling of power-loss switching the inverter devices precisely but
situations and sudden load changes. only when necessary.

12 - ACS 1000 ABB


DriveWare, the Tools to Increase Productivity

Easy-to-use ACS Family Tools

The ACS 1000 incorporates the same suite


of user-friendly tools as other drives of the
ACS product family. This makes it easier
when working with different ABB drives
in one plant.
The PC-based tools include DriveWindow,
DriveSupport and DriveOPC. They work
on-line and provide simple start-up, control,
monitoring and maintenance features.

DriveWindow Features
• Access to all drives connected to the
ABB’s DriveWindow is an advanced, easy-to- same network
use tool for commissioning and maintenance
of drive systems in different industries. • Graphical presentation of signal values
• Monitoring and editing of drive signals
and parameters off-line or on-line
• Back-up of drive parameters
File can be easily reloaded
• Fault diagnosis. Indication of drive
status and fault history
• Modbus compatibility, RS485

DriveSupport Features
• Diagnostics of faults and warnings
DriveSupport is a simple, clear and concise
multimedia-based service tool which provides • Testing and verifying possible fault causes
pictures and clear instructions for toubleshooting • Locating of faulty components
and servicing drives. DriveSupport makes
fault correction easier than ever before. • Performing step-by-step replacement
procedures
• Recording maintenance activities

DriveOPC Features
• Controlling and monitoring with PC-
DriveOPC is a software package which based process control software
allows communication between windows
applications and ABB drives. • Standard interface
• Remote connection via LAN (Local Area
Networks)
• Access to
• Drive control
• Signals and parameters
• Data and fault loggers

ABB ACS 1000 - 13


Issues and ACS 1000 Solutions

The ACS 1000 addresses customers concerns in all three areas indicated.

Supply Side Converter Motor

Basic drive system configuration

Supply Side Converter Motor


ACS 1000 Solutions ACS 1000 Solutions ACS 1000 Solutions
• Conforms to IEEE 519.1992 and • IGCT power semiconductor • Compatibility with standard
IEC 61000-2-4 technology for maximum asynchronous motors
• Fundamental power factor of reliability • DTC and output filter contribute
0.97 and constant total power • Small footprint to low audible motor noise
factor of 0.96 over entire speed • Complies with EMC legislation • No voltage stress and common
range • Sinusoidal output voltage and mode voltages on the motor
• Transformer can be placed current insulation
away from converter or outdoor
to keep its heat losses out of the
electrical building
• 24-pulse diode bridge rectifier
for more demanding networks

Benefits Benefits Benefits


• Avoids penalties and system • Highly reliable and highly • Avoids expense of “Engineering”
damage: efficient converter design a dedicated drive and designing
5th and 7th harmonics are • Retrofit-ready a new motor
suppressed by 12-pulse • Meets health and safety • No motor derating
diode bridge rectifier legislation • No voltage reflections with long
• Extra and costly reactive power • Prevents electromagnetic motor cables
compensation equipment is not emissions to neighbouring • Saves motor insulation, prevents
needed equipment motor bearing damages
• Only 6 transformer cables • No shielded motor cables
needed instead of up to 45 required
with multi-level configurations

14 - ACS 1000 ABB


Turgi

Reliability and Service

Dedicated ACS 1000 Test Facility

ABB knows how important reliability is to Th


your success. We are committed to ensuring
lar e AC
ind gest S 1
the reliability of every drive we deliver. To
this end, we have made a major investment
in a dedicated ACS 1000 test facility. for ustr driv 000
yo y. T es is
ur his se ba
You can be assured that your drive has been sp r c
thoroughly prepared for smooth integration ec mea vice ked
ific ns te b
into your facility. Simply reliable.
pla fas am y th
nt ter in e
ne se the
e d rv i
s. ce

Extensive Experience

As originators of AC drives technology in


the late 1960’s, ABB has over 30 years of
application know-how in all industrial sectors,
in virtually every country. We have gained
our experience by listening to our customers
and developing products which fulfill their
needs.

Whatever your industry, you will find ABB


engineers able to communicate in the language
View of ABB's test machines at the drive factory in Switzerland. of your business – not in drives jargon.
Every ACS 1000 drive will undergo a load test driving a medium
voltage motor with load, in order to subject it to 'real life' operating We listen. We learn. We deliver the best
conditions, before shipping it to customer's site. solutions. Your choice is simple.

Training Service and Commissioning

Extensive training can be provided for our ABB’s experts will help you sizing, designing
medium voltage drives customers at dedicated and comissioning your new drive.
ABB University centers in Asia, North America
and Europe. A range of training is offered In addition, our extensive worldwide service
from basic tutorials to programs tailored to network is at your disposal to ensure that your
your specific needs. drive and plant remain on-line when it most
www.abb.com/abbuniversity matters to you.

ABB ACS 1000 - 15


Comprehensive Service

• Drive sizing
• System design
• Application engineering
• Installation
• Commissioning
• Training
• On-board diagnostics
• Remote diagnostics
• Customized service programs
• Local technical support
• Local service support
• Spare parts & logistics network
• Worldwide service network
• 24 x 365 Support line

Our service experts are located in more than 55 countries


We provide service around the clock, around the world

Specifications subject to change without notice.


© Copyright 2005 ABB. All rights reserved.
3BHT 490 400 R0001 Rev. C

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
I-Net www.abb.com/motors&drives

16 - ACS 1000 ABB