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ABB Group

March 16, 2010 | Slide 1


EEE-CT 2010 CHLE
A New Medium Voltage Drive System
Based on ANPC-5L Technology
Michael Basler, ABB Switzerland Ltd, March 2010
ABB Group
March 16, 2010 | Slide 2
Overview
A new medium voltage drive system
The ANPC-5L topology
Converter configurations
System integration
Converter design
ABB Group
March 16, 2010 | Slide 3
New Medium Voltage Drive System
Overview
ACS 2000 launched by ABB in 2010
General purpose drive for standard
applications
Voltage source inverter
Medium voltage 6.6.9kV
Low power (400 kVA 1000 kVA)
Compact size
Multilevel GBT topology
Air cooled
Suitable for standard motors and input
isolation transformers
ABB Group
March 16, 2010 | Slide 4
New Medium Voltage Drive System
Overview
Suitable for use with or without input
isolation transformer
Direct-to-line connection
(transformerless) provides lowest cost
of ownership
Active Front End (AFE) for minimal line
side harmonics with power factor
correction and regeneration
Simple drive system integration
Three in - three out cabling for quick
and easy installation
Suitable for new or existing induction
motors
High reliability and low maintenance
costs
ABB Group
March 16, 2010 | Slide 5
The ANPC-5L Topology
General topology facts
ACS 2000 is based on a new 5-level VS topology
Different from existing 5-level topologies (ACS 5000)
Main reason: requirement for transformer-less operation
ACS 2000 topology combines two innovations for ABB MV-
drives
New innovative 5-level VS topology (from ABB CRC)
Dual switch HV GBT technology
ACS 2000 is exclusively available with an Active Front End
(AFE) to support.
either transformerless design or.
simple 2-winding transformer design
ABB Group
March 16, 2010 | Slide 6
The ANPC-5L Topology
General topology facts
5-level topology chosen in ACS 2000 is an extension of the
well-established 3-level VS
Main differences to 3-level VS topology include
Additional capacitor per phase "phase capacitor
NP diodes are extended by antiparallel active switches
Active Neutral Point Clamped (ANPC)
Phase capacitor is charged to of the total DC-link voltage
To provide an additional level in the output voltages
To have equally spaced steps in the output voltage
ABB Group
March 16, 2010 | Slide 7
The ANPC-5L Topology
From 3-level to 5-level topology
3-Level NPC VS (ACS 1000 or ACS 6000)
+V
DC
NP
-V
DC
PH
ABB Group
March 16, 2010 | Slide 8
The ANPC-5L Topology
From 3-level to 5-level topology
3-Level NPC VS
Phase output voltages
+VDC
NP
-VDC
VPH
ABB Group
March 16, 2010 | Slide 9
The ANPC-5L Topology
From 3-level to 5-level topology
3-Level NPC VS
Phase output voltages
+VDC
NP
-VDC
VPH
ABB Group
March 16, 2010 | Slide 10
The ANPC-5L Topology
From 3-level to 5-level topology
3-Level NPC VS
Phase output voltages
+VDC
NP
-VDC
VPH
ABB Group
March 16, 2010 | Slide 11
The ANPC-5L Topology
From 3-level to 5-level topology
From 3 levels to 5 levels:
+V
DC
NP
-V
DC
PH
ABB Group
March 16, 2010 | Slide 12
The ANPC-5L Topology
From 3-level to 5-level topology
From 3 levels to 5 levels:
+V
DC
NP
-V
DC
PH
1. Replacing GCTs with GBTs
ABB Group
March 16, 2010 | Slide 13
The ANPC-5L Topology
From 3-level to 5-level topology
From 3 levels to 5 levels:
V
dc
/2
+V
DC
NP
-V
DC
PH
1. Replacing GCTs with GBTs
2. Adding the Phase Capacitor
Charged to of the total
DC-link voltage
ABB Group
March 16, 2010 | Slide 14
The ANPC-5L Topology
Phase to ground voltage levels
5-Level ANPC VS
Phase output voltages
+VDC
NP
-VDC
+VDC/2
-VDC/2
VPH
ABB Group
March 16, 2010 | Slide 15
The ANPC-5L Topology
Phase to ground voltage levels
5-Level ANPC VS
Phase output voltages
+VDC
NP
-VDC
+VDC/2
-VDC/2
VPH
ABB Group
March 16, 2010 | Slide 16
The ANPC-5L Topology
Phase to ground voltage levels
5-Level ANPC VS
Phase output voltages
+VDC
NP
-VDC
+VDC/2
-VDC/2
VPH
ABB Group
March 16, 2010 | Slide 17
The ANPC-5L Topology
Phase to ground voltage levels
5-Level ANPC VS
Phase output voltages
+VDC
NP
-VDC
+VDC/2
-VDC/2
VPH
ABB Group
March 16, 2010 | Slide 18
The ANPC-5L Topology
Phase to ground voltage levels
5-Level ANPC VS
Phase output voltages
+VDC
NP
-VDC
+VDC/2
-VDC/2
VPH
ABB Group
March 16, 2010 | Slide 19
The ANPC-5L Topology
Phase to phase voltage levels
ABB Group
March 16, 2010 | Slide 20
The ANPC-5L Topology
Phase to phase voltage levels
ABB Group
March 16, 2010 | Slide 21
The ANPC-5L Topology
Phase to phase voltage levels
ABB Group
March 16, 2010 | Slide 22
The ANPC-5L Topology
Phase to phase voltage levels
ABB Group
March 16, 2010 | Slide 23
The ANPC-5L Topology
Phase to phase voltage levels
ABB Group
March 16, 2010 | Slide 24
The ANPC-5L Topology
Phase to phase voltage levels
The switching vectors are
symmetrical for the
negative side of the
waveform.
ABB Group
March 16, 2010 | Slide 25
The ANPC-5L Topology
Phase to phase voltage levels
0 0.005 0.01 0.015 0.02 0.025 0.03 0.035 0.04
-15
-10
-5
0
5
10
15
v
o
l
t
a
g
e

(
k
V
)
Converter phase to phase voltage
time(s)
ABB Group
March 16, 2010 | Slide 26
The ANPC-5L Topology
Controlling the phase capacitor voltage
Vdc/2
+VDC
NP
-VDC
PH
Some vectors produce the
same output voltage
V5 and V6 produce +V
CD
/2
V1 and V2 produce -V
CD
/2
Redundant vectors are
used to control the voltage
level of the phase capacitor
Current direction changes
in phase capacitor
V5
V6
ABB Group
March 16, 2010 | Slide 27
The ANPC-5L Topology
Network side
Active Front End (AFE) with nput Filter Unit (FU), di/dt clamp and
DC-link capacitors
+ + +
+
+
ABB Group
March 16, 2010 | Slide 28
The ANPC-5L Topology
Motor side
nverter unit (NU) with di/dt clamp and output filter for du/dt
limitation
ABB Group
March 16, 2010 | Slide 29
The ANPC-5L Topology
Protection against short-circuit
"Two Lines of Defense
Fast short-circuit protection on semiconductor level
f a gate-emitter voltage is applied during on-state
(saturation of GBT) a short circuit is detected and
turned off.
Protection firing on system level
Thyristor crowbar located in the DC link is operated to
discharge the DC link and phase capacitors.
Subsequently protection firing (turning on all GBTs) is
initiated.
Eliminates the possibility of GBT explosion
ABB Group
March 16, 2010 | Slide 30
Converter Configurations
Connection to external transformer
ABB Group
March 16, 2010 | Slide 31
Converter Configurations
Direct-to-line connection
ABB Group
March 16, 2010 | Slide 32
Converter Configurations
Direct-to-line connection
Control Unit
Control
UPS Power
Supply
Auxiliary Power Supply
MCB (Standard)
Close
Open
Trip
Main Power Supply
Motor
IM
Auxiliaries
Power Part
ACS 2000
ABB Group
March 16, 2010 | Slide 33
System ntegration
Requirements
Trends in the industry:
From an engineered solution to a more standardized
solution.
From a one of a kind solution to a commodity.
Standard drive interfaces
Motor side no special motor required
Line side meet common network standards
only simple input breaker needed
Controls HW level flexible /O's
SW level common ABB profile
Cooling Simple integration possible
ABB Group
March 16, 2010 | Slide 34
System ntegration
Drive system configurations
Main power supply
M
Main circuit breaker
Transformer
ACS 2000
Motor
Classic configuration
with
external transformer
M
Direct-to-line
(DTL)
connection
M M M
Several direct-to-line drives on a
common AC bus
ABB Group
March 16, 2010 | Slide 35
Converter Design
ACS 2000 converter
Cooling fan
Control unit
nverter Phase Modules
Active front end (AFE)
Phase Modules
Cable entry
ABB Group
March 16, 2010 | Slide 36
Converter Design
Cabinet front
Phase modules
Control unit
DC-link
Terminal field
nput filter choke
ABB Group
March 16, 2010 | Slide 37
Converter Design
Cabinet back
Output filter choke
DC busbar with di/dt clamp
Filter resistors
nput filter choke
ABB Group
March 16, 2010 | Slide 38
Converter Design
Phase module
Connectors
Phase interface
control board
Phase
capacitor
ABB Group
March 16, 2010 | Slide 39
Converter Design
Phase module
Phase
capacitor
Low
inductive
busbar
GBT
modules
Gate units
Heatsink
ntegrated
current
sensor
ABB Group
March 16, 2010 | Slide 40
Converter design
Main features
Compact size
Ease of service
Redundant cooling
Front access to all
components
Phase module exchange in
less than 30 minutes
Modular design
ABB Group
March 16, 2010 | Slide 41
A New Medium Voltage Drive System Based on ANPC-5L
Technology
Conclusion
ACS 2000 was successfully launched on the market
ntroduction in waves to ensure smooth market introduction
Stages Countries Internal launch
1st wave UK, SE, ES, T, CZ, PL Q2, 2009
2nd wave Rest of Europe Q3, 2009
3rd wave NAS & SAS Q1, 2010
4th wave SAM, NAM & MEA Q2, 2010
Successful collaboration between research and industry
Second presentation on ACS 2000
PE-3: Power Electronics Part 3
Tuesday 16, 11:50-12:10
A New Medium Voltage Drive System Based on ANPC-
5L Technology (VF-009288),
Frederick Kieferndorf