Medium Voltage AC Drives for Speed and Torque Controlof 315–5000kW Asynchronous Motors

DriveIT ACS 1000

ABB2 - ACS 1000

ABB ACS 1000 - 3

Simplified Performance

Drawing from over a century of industrialmanufacturing experience, ABB provides asimple, reliable approach to electronic powercontrol: the ACS 1000 medium voltage drivefor speed and torque control of 315 – 5000kWasynchronous motors for voltages of 2.3, 3.3and 4.0kV.

• Retrofit-readyfor existing motors and suitable formost medium voltage applicationsincluding pumps, fans, compressors,extruders, conveyors

• Output sine filterfor pure sinusoidal voltage and currentoutput: standard motors, no motorderating, no voltage stress and nocommon mode voltages on the motorinsulation

• IGCT power semiconductorsfor highest reliability

• Fuseless designfor reliable, non-aging, maintenance-free circuit protection.

• DTC control platform for exceptionallyhigh torque and speed performance

Key Product Features

Rugged Reliability

We know that reliability is of paramountimportance. The low component count ofthe ACS 1000 makes it inherently morereliable. Furthermore, we test each componentindividually and load test every drive beforedelivery.

Smooth System Integration

The ACS 1000 is retrofit-ready with a varietyof flexible options you can choose according toyour needs. Network harmonics and disturbancesto existing electrical equipment are minimized.Standard motors can be used without anyderating or need for special motor insulation.

High Levels of Performance

The ACS 1000 delivers precise process controlthrough ABB’s patented Direct Torque Control(DTC) technology. DTC can provide the quickesttorque step response of any motor controlplatform. This ensures the highest controlaccuracy without the use of an encoder, despiteinput power variations or sudden load changes.

Comprehensive Service

We have the largest service organizationworldwide which backs every drive wedeliver. From training to technical support,we stand ready to provide you with a com-prehensive program of service options.

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

Isolationtransformer

Inductionmotor

FilterInverterDC LinkRectifier

ABB4 - ACS 1000

Retrofit-ready Simplicity

The ACS 1000 is optimized for retrofits.With its small footprint and input isolationtransformer flexibility the drive can fit whereyou need it. Its enhanced motor identificationroutine simplifies the start-up procedure bydetermining all the key motor parametersautomatically – simply enter the motor nameplate data and the ACS 1000 does all the rest.Thanks to the perfectly sinusoidal outputwaveform existing asynchronous motors canbe used without derating. The design alsoensures that the motor is not subjected toharmful common mode voltages. This meansspecial motor insulation is not required.

Smooth System Integration

Clean Integration into Existing Systems

Due to its on-board macros and user-friendlysoftware tools, the ACS 1000 is probably thefastest commissioned medium voltage drivein the world.

ABB offers an open communication strategyenabling connection to a PLC or a DCS system.Fieldbus connectivity with a wide variety ofprotocols is available.The ACS 1000 meets the IEEE 519-1992 andIEC 61000-2-4 specifications for voltage andcurrent harmonic distortion for virtually allinstallations. This eliminates the need forexpensive harmonic filters and protects otherelectrical equipment from harmonic distur-bances.

The ACS 1000 meets EN (IEC), CE, UL, cULand other standards to ensure smooth systemintegration worldwide.

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

0

VoltageCurrent

• Retrofit-ready• Sinusoidal output• Low network harmonics• High power factor• Small footprint• Fast commissioning• EMC compliant• Gentle on system components

ACS 1000 System Integration System Design Flexibility

The ACS 1000 can be configured with eitheran integrated dry-type or separately installedinput isolation transformer. This flexibilityenables the use of oil filled transformers whenthe transformer will be mounted outdoors.The advantage is that you are not forced toaccept dissipated heat losses from the inputisolation transformer in the electrical room.

• Ensures sinusoidal voltage andcurrent output on the motor side

• Provides compatibility with standardasynchronous motors

• Avoids need to derate motor• Eliminates voltage stress and

common mode voltages tothe motor insulation

• Reduces motor noise• Allows using existing

non-shielded cables

Output Sine Filter

ABB ACS 1000 - 5

The Principle of Industrial IT

IndustrialIT and DriveIT

ABB’s IndustrialIT means increasedstandardization and seamless interactionof different ABB products.The ACS 1000 has been certified to bearthe IndustrialIT Enabled symbol, a specialmark indicating that the drive can be easilyintegrated into the IndustrialIT architecturein a ‘plug & produce’ manner.Read more in IndustrialIT for Drives(Brochure 3AFE 64572491 Rev A).

• Easy integration of the drive intocustomer industrial environment

• All drive information readily availablein electronic form

• Drive communication with theenvironment through control panels,standardized fieldbus adapters andinterfaces (OPC, OLE for ProcessControl)

• Easy to use start-up and maintenance tools

Benefits

ProcessControllers

Customer support systemsfor product training, helpdesk, service

Business systems forsourcing, ordering,spare parts

Software for dimensioning,configuration, start-up,monitoring, documents

Software tools for energycalculations, efficiencyanalysis, new drive selection

Low VoltageAC Drive

Medium VoltageAC Drive

Electricalmachinery inthe process

ApplicationController

Fieldbus

ControlNetwork

ABB6 - ACS 1000

Streamlined Technology

The Medium Voltage Challenge

Until now, the power switches for mediumvoltage drives have been either Gate Turn OffThyristors (GTO) or Insulated Gate BipolarTransistors (IGBT). For medium voltage app-lications, such devices force design trade-offsthat increase the cost and complexity of powercontrol systems. ABB is intimately familiar withthese trade-offs. We have invested in and furtherdeveloped these devices for many years.

IGBT: Conventional Transistorized Approach

Both low voltage and high voltage IGBTshave been used in medium voltage drives.IGBTs are fast switching but conduction lossesare high at medium voltage levels and com-plicated series connections of multiple IGBTsare required. High voltage IGBTs have fewerseries-connected devices relative to low voltageIGBTs, but conduction losses are even higher.Overall parts count increases resulting in biggerdrives. Costs go up. Reliability goes down.

GTO: Thyristor Standard

GTO technology is reliable and conductionlosses at medium voltage levels are tolerable.The problem is that non-homogeneousswitching requires huge additional circuitryfor turn off. Again, parts count increasesresulting in larger drives. Costs increase.Reliability decreases.

IGCT: Specifically Designed forMedium Voltage

ABB is keenly aware of the need for a power-switching device that displays:• High-speed switching like an IGBT• Low-loss conduction like a GTO• Reliability in a wide range of medium

voltage applications

ABB has developed the simple solution basedon proven technology: the Integrated GateCommutated Thyristor (IGCT). This evolutionarytechnology consists of a redesigned GTO, whichincorporates significant design breakthroughs.The new IGCT delivers fast, homogeneousswitching and inherently low losses.The IGCT is used with Voltage Source Inverter(VSI) topology which is intrinsically lesscomplex and more efficient compared

to other topologies. The IGCT-basedACS 1000 meets the complex

medium voltage drivechallenge.

IGCT power semiconductors for highest reliability and performance

ABB ACS 1000 - 7

Streamlined Technology RequiresFewer Parts

Depending on the voltage level, an IGCT-based medium voltage drive typically requiresas little as one fifth the number of powersemiconductor devices as existing low voltageIGBT solutions. IGCT’s lower losses meanless cooling equipment and higher inherentreliability. Fewer parts. Higher reliability.Simple solution.

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 mosttechnology 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 losseslosses

High switching losses Low switching losses Moderate switching Low switchinglosses losses

Low switching High switching High switching High switchingfrequency frequency frequency frequency

Snubbers required Snubberless but Snubberless but Snubberlessrequires synchronized requires synchronizedgate driver gate driver

Separate gate driver Compact gate driver Compact gate driver Integrated gatedriver

Power Safe from Additional protection Additional protection Safe fromcircuitry 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 compactdesign to reduced reliability

and large equipmentsize

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

IGCT greatly improves performance

and reliability – extending beyond

conventional solutions.

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The ACS 1000 Medium Voltage AC DriveAir-cooled

Cooling air intake

Small footprint and no rear or sideaccess required for less floorspace and increased retrofitflexibility

EMC compliantcabinet for problem-free operation inelectro-magneticevironment

Electromechanicallyinterlocked doors ofpower sections forsafety

DC bus groundingswitch for safety

Control section• Same layout for air-cooled and

water-cooled units

User-friendly control panel forlocal operation• Keypad with multi-language

display• Main supply on/off pushbuttons• Emergency stop pushbutton

ABB ACS 1000 - 9

Control electronicsmounted on swing

frame for easy access

Electronic power supply –battery backed-up for

maximum reliability

Application and motorcontrol board with fast

digital signal processorand DTC

Fiber optics for noiseimmunity and galvanic

isolation

Standard andoptional I/O boards for

greater functionality

Battery back-up forelectronic power supply

Integrated fan for lownoise level

IGCT powersemiconductors forhighest reliability andperformance

Output filter for smoothsinusoidal current andvoltage waveform

Seperated connectionsection for powercables

Top and bottom cableentry/exit as standard

12-pulse input bridgeas standard24-pulse input bridgeas option, for stringentharmonic mitigation

Rear view

Front view

ABB10 - ACS 1000

The ACS 1000 Medium Voltage AC DriveWater-cooled

Small footprint for less floor spaceand increased retrofit flexibility

EMC compliantcabinet for problem-free operation inelectro-magneticevironment

Electromechanicallyinterlocked doors ofpower sections forsafety

DC bus groundingswitch for safety

Control section• Same layout for air-cooled and

water-cooled units

User-friendly control panel forlocal operation• Keypad with multi-language

display• Main supply on/off pushbuttons• Emergency stop pushbutton

ABB ACS 1000 - 11

Control electronicsmounted on swing

frame for easy access

Electronic power supply –battery backed-up for

maximum reliability

Standard andoptional I/O boards for

greater functionality

Battery back-up forelectronic power supply

IGCT powersemiconductors forhighest reliability andperformance

Output filter for smoothsinusoidal current andvoltage waveform

Seperated connectionsection for powercablesTop and bottom cableentry/exit al standard

12-pulse input bridgeas standard24-pulse input bridgeas option, for stringentharmonic mitigation

Rear view

Front view

Inverter stacks onswing frame for easyaccessibility andperformance

Water cooling cabinetincorporating: main,secondary and watertreatment sub-systems• Accessible during drive

operation• Design allows for service

without the need to drainthe water circuit

• Redundant pump optional

Application and motorcontrol board with fast

digital signal processorand DTC

Fiber optics for noiseimmunity and galvanic

isolation

ABB12 - ACS 1000

Performance

DTC Technology at the Heart of the ACS 1000

Direct Torque Control (DTC) is an optimizedmotor control method for AC drives that allowsdirect control of all the core motor variables.This opens up AC drive capabilities neverbefore realized and offers benefits for allapplications.

What is Direct Torque Control?

Direct Torque Control (DTC) is a revolutionarymotor control method for AC drives that allowsaccurate control of both motor speed andtorque without pulse encoder feedbackfrom the motor shaft.

In DTC, stator flux and torque are used asprimary control variables. The motor statecalculations are updated 40,000 times asecond (i.e. every 25 µs) in the advancedmotor software model by the high-speeddigital signal processor. Due to the continuousupdating of the motor state and the comparisonof the actual values to the reference values,every single switching in the inverter isdetermined separately.

Maximized Starting Torque

Precise torque control provided by DTCallows the ACS 1000 to provide maximizedstarting torque that is both controllable andsmooth.

Fast Response to Mains Fluctuations andProcess Side Changes

The exceptionally fast torque step responseof the ACS 1000 means that it can respondto process and mains changes extremely fast.This enables easy handling of power-losssituations and sudden load changes.

Reduced Noise

Because of the separately determined switching,the ACS 1000 has no fixed switching frequency.This eliminates resonances that cause irritatingnoise associated with AC drives using conven-tional PWM technology.

Typical torque (T) response of a DTC drive, compared with fluxvector control and open loop pulse width modulation (PWM)

ABB ACS 1000 - 13

DriveWare, the Tools to Increase Productivity

Easy-to-use ACS Family Tools

The ACS 1000 incorporates the same suiteof user-friendly tools as other drives of theACS product family. This makes it easierwhen working with many different ABBdrives in one plant.The PC-based tools include DriveWindow,DriveSupport and DriveOPC. They workon-line and provide simple start-up, control,monitoring and maintenance features.

DriveWindow

ABB’s DriveWindow is an advanced, easy-to-use tool for commissioning and maintenanceof drive systems in different industries.

DriveSupport

DriveSupport is a simple, clear and concisemultimedia-based service tool which providespictures and clear instructions for toubleshootingand servicing drives. DriveSupport makesfault correction easier than ever before.

DriveOPC

DriveOPC is a software package whichallows communication between windowsapplications and ABB drives.

• Access to all drives connected to thesame network

• Graphical presentation of signal values

• Monitoring and editing of drive signalsand parameters off-line or on-line

• Back-up of drive parametersFile can be easily reloaded

• Fault diagnosis. Indication of drivestatus and fault history

• Modbus compatibility, RS485

Features

• Controlling and monitoring with PC-based process control software

• Standard interface

• Remote connection via LAN (Local AreaNetworks)

• Access to• Drive control• Signals and parameters• Data and fault loggers

Features

• Diagnostics of faults and warnings

• Testing and verifying possible fault causes

• Locating of faulty components

• Performing step-by-step replacementprocedures

• Recording maintenance activities

Features

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Issues and ACS 1000 Solutions

Basic drive system configuration

ACS 1000 Solutions

• Compatibility with standardasynchronous motors

• DTC and output filter contributeto low audible motor noise

• No voltage stress and commonmode voltages on the motorinsulation

Motor

ACS 1000 Solutions

• IGCT power semiconductortechnology for maximumreliability

• Small footprint• Complies with EMC legislation• Sinusoidal output voltage and

current

Converter

ACS 1000 Solutions

• Conforms to IEEE 519.1992 andIEC 61000-2-4

• Fundamental power factor of0.97 and constant total powerfactor of 0.96 over entire speedrange

• Transformer can be placedaway from converter or outdoorto keep its heat losses out of theelectrical building

Supply Side

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

MotorConverterSupply Side

Benefits

• Avoids expense of “Engineering”a dedicated drive and designinga new motor

• No motor derating• No voltage reflections with long

motor cables• Saves motor insulation prevents

motor bearing damages• No shielded motor cables

required

Benefits

• Highly reliable and highlyefficient converter design

• Retrofit-ready• Meets health and safety

legislation• Prevents electromagnetic

emissions to neighbouringequipment

Benefits

• Avoids penalties and systemdamage:5th and 7th harmonics aresuppressed by 12-pulsediode bridge rectifier

• 24-pulse diode bridge rectifierfor more demanding networks

• Extra and costly reactive powercompensation equipment is notneeded

• Only 6 transformer cablesneeded instead of up to 45with multi-level configurations

ABB ACS 1000 - 15

The ACS 1000 is backed by the

largest drives service team in the

industry. This means faster service

for your specific plant needs.

Reliability and Service

Dedicated ACS 1000 Test Facility

ABB knows how important reliability is toyour success. We are committed to ensuringthe reliability of every drive we deliver. Tothis end, we have made a major investmentin a dedicated ACS 1000 test facility.

You can be assured that your drive has beenthoroughly prepared for smooth integrationinto your facility. Simply reliable.

Extensive training can be provided for ourmedium voltage AC drives customers at dedi-cated ABB Automation University centers inAsia, North America and Europe. A rangeof training is offered from basic tutorials toprograms tailored to your specific needs.

Training

Our Training Centers around the world: New Berlin, USA;Turgi, Switzerland; Bangkok, Thailand; Beijing, ChinaTake a look at: www.abb.com/automationuniversity

The ACS 1000 factory test sequence

1.

Insulationtest

2.

Controltest 3.

Powerequipment

test

4.

Loadtest

Service and Commissioning

ABB’s experts will help you sizing, designingand comissioning your new drive.

In addition, our extensive worldwide servicenetwork is at your disposal to ensure that yourdrive and plant remain on-line when it mostmatters to you.

Extensive Experience

As originators of AC drives technology inthe late 1960’s, ABB has over 30 years ofapplication know-how in all industrial sectors,in virtually every country. We have gainedour experience by listening to our customersand developing products which fulfill theirneeds.

Whatever your industry, you will find ABBengineers able to communicate in the languageof your business – not in drives jargon.

We listen. We learn. We deliver the bestsolutions. Your choice is simple.

ABB16 - ACS 1000

ABB Switzerland LtdMedium Voltage AC DrivesCH-5300 Turgi / Switzerland

Tel +41 (0)58 589 27 95Fax +41 (0)58 589 29 84Email mvdrives@ch.abb.comI-Net www.abb.com/motors&drives

Our service experts are located in more than 55 countriesWe provide service around the clock, around the world

• 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

Comprehensive service

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