—

MODR, LV DRIVES

Variable Speed Drives

Ebram Helal
—
Electricity Distribution Network :

Residential Voltage Levels Industrial Voltage Levels

Single phase (220 Volt) Three Phase
Three Phase (380 Volt) 1- 380 Volt
2- 500 Volt
3- 690 Volt
4- 3.3 KV
5- 6.6 KV
6- 11 KV
7- 22 KV
—
Types of Electrical Loads in Power System

• Domestic load
• Commercial load
• Industrial load (Represent the highest Load on the electrical
network.)
—
Types of Motors

As the motors form a high portion of the industrial load, so we must

understand the nature of this significant load.

DC Motors
AC Motor
1. Series Wound
1. Synchronous
2. Shunt Wound
2. Asynchronous (induction)
3. Compound Wound
4. Permanent Magnet
 —
Common motor starting methods

Direct-on-line starting Star-delta starting

(DOL)

Motor soft starter Starting with AC drive

© ABB Group
September 1, 2021 | Slide 5
 —
General benefits of AC drives Reduced maintenance

AC drive enables:
– soft and controlled starting, stopping and operation of motor
• reduced mechanical resonances/stresses – longer lifetime of conveyors,
fans, pumps and other mechanical equipment
• in pump applications, no hammer effect to pipelines – fewer repairs
• lower pressure in the pipeline – reduced leakages
– use of squirrel cage induction motors
• Robust and simple construction – minimal need for maintenance
• Good weight-power ratio
• Standardized – motors of different manufacturers have same dimensions
• High protection classes (e.g. IP54)
Driven machine can be operated in its most efficient operating point or area, meaning that the machine runs
cooler and thus its lifetime is extended

© ABB Group
September 1, 2021 | Slide 6
 —
Different names and acronyms

VSD = variable speed drive

ASD = adjustable speed drive

VFD = variable frequency drive

AFD = adjustable frequency drive

VVVF = variable voltage variable frequency

Frequency converter
Inverter
AC drive

© ABB Group
September 1, 2021 | Slide 7
 —
Drives Main construction

Complete AC drive consisting of:

1-Rectifier
2-DC voltage intermediate circuit,
3-Inverter
4-control electronics

DC voltage
Rectifier Intermediate circuit Inverter

U1 U2
V1 V2
W1 W2
—
Main components of AC drive

▪ An AC drive converts mains current and voltage with fixed

frequency and amplitude into current and voltage with
variable frequency and amplitude
▪ An AC drive consists of rectifier, DC voltage intermediate
circuit, inverter and control electronics
▪ Control electronics control the operation of an AC drive

DC voltage
Rectifier intermediate circuit Inverter

L
U1 C U2
V1 Ud Udc V2
W1 W2

User interface: Actual

eg, control panel or signals
automation system Control electronics
Control
signals

© ABB Group
September 1, 2021 | Slide 9
 —
Rectifier
Function and types

▪ A rectifier converts mains voltage (AC) into DC voltage

▪ Rectifier types include:
▪ Diode rectifier
▪ Thyristor rectifier
▪ IGBT rectifier

© ABB Group
September 1, 2021 | Slide 10
—
Rectifier Diode rectifier

E
Most common diode rectifier consists of
six diodes (6-pulse diode bridge)
– Energy (E) can flow only in one
U1
V1
direction, from network to motor
W1 – Diode bridges can be parallel-
connected in order to increase power
and/or lower harmonics in supply
network by using phase shifting
transformer
– Power factor close to unity (1)

© ABB Group
September 1, 2021 | Slide 11
 —
Rectifier Thyristor rectifier

U1
V1
W1

Thyristor bridge has six thyristors

– Typically consists of one motoring and one regenerative
thyristor bridge
– Energy can flow in two directions
– Power factor in motoring mode is close to unity and
in braking mode typically 0.85

© ABB Group
September 1, 2021 | Slide 12
—
Rectifier IGBT rectifier

E Consists of six IGBTs and six diodes

Energy can flow in two directions
– When braking, energy is fed back to supply
network
U1
V1 Switching of IGBT is controlled by an
W1 IGBT control program and control
electronics
Requires a filter in front of the IGBT rectifier
for proper operation
Power factor is unity (1.0)

© ABB Group
September 1, 2021 | Slide 13
—
AC drive types Multidrive

U1 Multidrive is an AC drive that consists of

V1 one rectifier (supply unit) and several
W1
inverters connected to a common
DC voltage intermediate circuit
Each inverter is able to operate
independently
Braking energy from braking motors is
fed into common DC bus for use by
other motors

© ABB Group
September 1, 2021 | Slide 14
—
Electrical braking

Braking energy has to be dissipated or fed into supply network

With diode rectifier it is not possible to feed braking energy into
supply network. Energy has to be dissipated using braking
chopper and braking resistor connected to DC voltage
intermediate circuit of AC drive.
With IGBT or thyristor rectifiers the braking energy can be fed to
supply network

U1 U2 U1 U2
V1 V2 V1 V2
W1 W2 W1 W2

Chopper Actual
signals
Control electronics
Control
signals
Resistor

© ABB Group
September 1, 2021 | Slide 15
—
Drives Structure

ACS800-01 & -11 ACS800-02, ACS800-04, ACS800-07, ACS800-17, ACS800-37,

Wall mounting Pedestal mounting Modules for Panel Cabinet mounting Cabinet mounting Cabinet mounting with
builder with DSU with regenerative ISU low harmonic ISU
—
ABB Drives
—
Drive Products – At a glance

We are the leading drives manufacturer with focus on domain expertise and reliability

#1 global manufacturer of AC drives

~2,500 employees worldwide
1,7 million drive and PLC products manufactured in a year
80+ countries with local representatives

ABB factory Regional Distribution Center (RDC)

1. Total R&D workforce includes only internal employees
Sales EMS factory

September 1, 2021 Slide 18

September
Slide 19 1, 2021

ABB Values

Courage Care Curiosity Collaboration

At ABB, we: At ABB, we: At ABB, we: At ABB, we:
– Take action and manage – Take care of our customers, – Believe there is always – Believe smart people collaborate
consequences our people and the environment a better way
– Build on each other’s strengths
– Speak up and ask for help – Respect and value differences – Lead with technologies and successes
and innovations
– Take calculated risks to create – Do what is right and act – Partner with our customers
success with integrity – Learn from failures
and successes

ABB Industry Oy basic4e.ppt 19

September
Slide 20 1, 2021

Drive Products – Main markets

Who we are Where we play How we do it

Light industries Food and beverage, Reliability, performance, support

Reducing cost by discrete production,
saving energy plastics, ceramics, etc. We are the product of choice
for our end customers

Heavy industries Oil and gas, power

Running critical production metals, mining, Geographical coverage,
process chemical, cement, pulp value beyond products
at best performance and paper, etc. and value-added services
Leading supplier of AC drives and
PLC for light and heavy industries, We are the supplier of choice for
infrastructure, our channels and partners
integrators and machine builders. Machine building Cranes, mixers,
Delivering high performance compressors, extruders,
We are market leader in <600kW and reliable components conveyers, pumps, fans, etc.
drives with history of manufacturing Domain expertise and application
drive for more than 45 years. know-how
Infrastructure Water and air handling We are the trusted partner for
Reducing cost by saving applications in buildings, helping our customers’
energy utilities and industrial applications applications to work optimally

ABB Industry Oy basic4e.ppt 20

September
Slide 21 1, 2021

Drive Products – The forerunner of technology

Cornerstones of innovation

Over 45 years of experience

2020
2019 Control
2014 Dedicated panel with
2011 Solar pump ultra-low narrowband
harmonic network
2009 All- focused
offering connectivit
2006 LV drive compatible drive for HVAC y
2004 platform and Water
Servo with IEC
segments
2002 Standard performance programming
1995 LV AC drive LV AC drives inside AC500 PLC
Regenerativ IoT
1992 Direct e LV drive with intuitive Modular and
connectivity
user scalable
1985 First PLC torque interface offering
AC500 PLC
1975 Frequency with control
platform
1971 Low power converter
distributed (DTC)
machinery
1969 First ABB PWM drive based on safety
PLC digital
AC drive circuits
launched
development
started

ABB Industry Oy basic4e.ppt 21

—
Our offering
September
Slide 23 1, 2021

Drive Products
Product portfolio by product line

Industrial Machinery & Micro PLC & HMI

– Wall mount Drives – Drives for machine – Advanced Functional
– Drives modules building safety
– Ultra low harmonic drives – Advanced Position control – Certified Security
– Regenerative drives – Application ready features – Harsh environment
– Advanced IEC program – Connectivity ready – Motion Control
– Advanced Functional
safety

Segment specific General Purpose Customer value

HVAC and Water and – Wall mount Drives Beyond products
wastewater – Drives modules – Smart Guides
– Wall mount Drives – Cabinet Drives (Digital manuals)
– Drives modules – Functional safety – Guided selection tools
– Ultra low harmonic drives
– Energy efficiency
– Cabinet Drives calculators
– Segment specific features
– Remote apps

Domain expertise and the right products for the right markets

ABB Industry Oy basic4e.ppt 23

September
Slide 24 1, 2021

Drive Products
Industrial drives

Uncompromised productivity
ACS880-04/14/34/…
– High performance, safety and Drive modules
configurability with world class services
– Our benchmark of performance, expertise ACS880-31
and quality Ultra-low harmonic
drives
– Application ready product for Cranes,
Winders, Artificial lifting, Centrifuges
and Position control and more ACS880-11
Regenerative
– Scalable and flexible programmability drives
– Advanced Functional Safety
ACS880-01
Wall mount drives

ABB Industry Oy basic4e.ppt 24

September
Slide 25 1, 2021

Drive Products
Machinery & Micro

Persistent and adaptable performance ACS380-04

Drives for cabinet
– Specifically designed to offer high installation
performance, adaptability and reliable
operation to machine builders
– Customers can configure and optimize
the units to match exactly their needs –
they get all they need with a great motor
control accuracy and performance ACS880-M04

– Designed specifically for machine builders Drives

for Machinery
and system integrators applications
– Part of all-compatible product family
– Integrated functional safety

ABB Industry Oy basic4e.ppt 25

September
Slide 26 1, 2021

Drive Products
Segment specific drives for Water and wastewater

Securing the flow of water and wastewater

ACQ580-07
– The most complete offering for water and Cabinet drives
wastewater
– Optimized efficiency even in demanding ACQ580-04/34
environments
Drives modules
– Effortless commissioning and
configuration
– Smart embedded functions ACQ580-01
for uninterrupted operation Wall mount drives
– Application expertise and life cycle
services to keep the water flowing ACQ580-31
Ultra low harmonic
drives

ABB Industry Oy basic4e.ppt 26

September
Slide 27 1, 2021

Drive Products
Segment specific drives for HVACR

Comprehensive climate control

ACH580-07
– The most complete offering for HVACR Cabinet drives

– Designed for the HVAC market and has all you need built inside
– Speak the languages our HVAC customers and their systems do ACH580-04/34

– Quality that has been proved with over 600.000 running Drive modules
installations worldwide
ACH580-31
Ultra-low harmonic
drives

ACS880-01
Wall mount drives

ACH480-04
Drives for cabinet
installation

ABB Industry Oy basic4e.ppt 27

September
Slide 28 1, 2021

Drive Products
General purpose drives

Effortless energy efficiency

ACS580-07
– One product, many applications – includes the all essential Cabinet drives
and much more for typical light industry applications
– Instant availability from central stocks around the world
ACS580-04
– Product including all essential components minimizes the
Drive modules
commissioning and setup time

ACS580-01
Wall mount drives

ACS480-04
Drives for cabinet
installation

ABB Industry Oy basic4e.ppt 28

September
Slide 29 1, 2021

System Drives
Product portfolio

General Performance Renewables

ACS580MV ACS5000 / MEGADRIVE LCI ACS880-77/87 PCS6000

– 200 kW to 6.3 MW – 2 to 36 MW – 800 kW to 8 MW – 3 to 12 MW
– Applications: pumps and fans – Applications: large compressors, – Application: onshore – Application: medium voltage
– Simple to select, order, pumps, fans and GT starters and offshore wind turbines wind turbine converter
commission and use – Flexible to configure – Customer specific designs – Flexible to configure
– All-Compatible user interface for specific needs – Compact and cost efficient for specific needs
– Affordable energy saving – Medium to high power – Grid code compliance – High performance
solution single drives and simulations – High reliability and availability
– High reliability and availability – Modular design for high – Highest level of personal safety
– Highest level of personal safety availability and high efficiency

ABB Industry Oy basic4e.ppt 29

September
Slide 30 1, 2021

System Drives
Product portfolio

Industrial Drives Drive Modules

ACS880 cabinets ACS1000/ACS2000 ACS6080/ACS6000 ACS880 modules HES880

– 1.5 to 5200 kW – 315 kW to 5 MW / 250 kW – 5 to 36 MW – 1.5 to 3200 kW – 320 to 900A / 230
– Applications: paper to 3.68 MW – Applications: mills, – Designed for OEM’s, to 500Vac
machines, winders, – Applications: pumps, propulsion, conveyors, system integrators – Applications:
rolling mills, conveyors, fans, mills, conveyors, hoists, test stands and panel builders working machines,
hoists, cranes, extruders, mixers, hoists – Flexible to configure – Easy to integrate marine, harsh
propulsion, etc. – Flexible to configure for specific needs – Flexible to configure environment industrial
– Versatile with full for specific needs – Supporting multiple for specific needs – Small size and weight
functional safety – Small footprint motors – Cyclic load tolerance
– Best in class motor – High reliability – High performance – Ultra-low harmonic drive
control and high and availability – High reliability – 4 g vibration and 30g
performance – Highest level and availability shocks, IP67
– Built-in reliability of personal safety

ABB Industry Oy basic4e.ppt 30

September
Slide 31 1, 2021

DC Drives
Product portfolio

DC Drives

DCT880 modules/cabinets DCS880-S modules DCS880-A cabinets

− 20-4200 AAC − 20-5200 ADC, 1000 VAC − Up to 20 kADC and 1600 VAC
− Thyristor power controller with power − Applications: cranes, extruders, winders, mill − Applications: cranes, extruders, winders, mill
optimization stands, centrifuges, test benches, elevators, stands, centrifuges, test benches, elevators,
− Applications: Electrical heating, egannealing, electrolysis electrolysis
drying, melting or heating in glass, plastic and − Flexible configuration − Enclosed Converter
metal industry
− Extended connectivity − Complete pretested
− Better process control and reduced CO2 − Integrated field exciter − Short power down time
emission compared to fossil fuel heating
− Easy programming − Hard parallel configurations up to 20kA
− Power optimizer
− Highest level of functional safety − High power solutions in 6- and 12-pulse
− Extended connectivity as 880-platform

ABB Industry Oy basic4e.ppt 31

—
Drives Service – You choose, we respond. Globally
—
Services to match your every need
Long-term commitment to maintain your assets

Rapid response Lifecycle management Operational excellence Performance improvement

Fast and flexible response Powerful tools and knowledge Manage your assets, Optimized connectivity,
to maximize your to optimize and extend your operations, and risk to deliver reliability and efficiency
equipment uptime equipment life strategic business results of your assets to increase
speed and yield

We are your planning and operations partner for services and solutions

September 1, 2021 Slide 33

—
You choose, we respond. Globally

ABB is a reliable service partner

Over 600 ABB field service engineers

Services in more than 60 countries
500 service partners
Over 10 million drives delivered
Providing services for drives for almost 40 years

Global Service Center (4) ABB or partner service

Regional Service Center (8) Covered by closest HUB

September 1, 2021 Slide 34

—
ABB Drives Service Portfolio
From spare parts to cloud-based condition monitoring

– Global ABB service units, – ABB Drive Care

complemented by ABB authorized Service Agreements
– Traction Bordline
value providers, cover your
installation throughout its lifecycle

Installation and Training Spares and Maintenance Technical Support

– Maximize performance, uptime Commissioning – Drive Training Consumables – Preventive Maintenance and Repairs
and efficiency throughout the life – Installation – Spare Parts – ABB Ability™ Life Cycle – Workshop Repair
Commissioning Drive Exchange Assessment On-Site Repair
cycle of your assets – –
– Extended Warranty – Inspection
–
– Technical Support
and Diagnostics
– ABB Ability™ Remote
– Reconditioning Assistance

– From spare parts and technical

support to cloud-based condition
monitoring solutions, ABB offers
the most extensive service offering Engineering Advanced Extensions, Upgrades End-of-Life Replacements
to fit your needs and Consulting Services and Retrofits Services – Replacement
– Drive Engineered Solution – ABB Ability™ Energy – Drive Hardware Upgrade – Disposal and Recycling – DC Drives
– Test Rig Solutions Optimization – Drive Control Upgrade
– Drive & Engineering – ABB Ability™ Condition – Drive Retrofit
Consulting Monitoring
– 3rd Party Modernization

September 1, 2021 Slide 35