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Power PartPower PartACS 5000 Air Cooled

Service & Commissioning

Course G740

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-ObjectivesPower part

Upon completion of this part the student will be familiar with:

� Main circuit diagram

� Location and function of components

� Operation principle of 5-level topology

� Communication between INU and COU

� Protection functions

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-Drive topology

MCB

Input transformer(s)6 secondaries10°phase shift

3-ph.MV

supply

12 pulses diode rectifier on each phase

H-bridge inverter on each phase, with a common star point

2 x 3-level inverter cells per H-bridge

Phase 3

Phase 2

Phase 1

Power part

ACS 5000 consists of three phase modules (INU1, INU2, INU3).

Each phase module supplies one of the motor phases, and represents the equivalent of a single phase inverter (H-bridge), with a 12 pulses diode rectifier as a front end.

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-Drive topology

12 pulses diode rectifier on each phase H-bridge inverter

on each phase, with a common star point

L1

L3

IGCT with RC diodeM

L_P

MotorPhase

StarPoint

M M

L_P1

L_N1

ACS 5000 MV Variable Frequency Drive

36-pulseRectifier

- DC-Link 5-level Inverterand dv/dt Filter-x1L1

x1L2x1L3

x2L1x2L2x2L3

Rectifierx=1

x=2

x=3

L2

MR

L_N

INU3

INU2

INU1

3-level inverter cell

L1L2

L3

M

Inverter Star Point

+DC

- DC

NP

+DC

- DC

NP

+DC

- DC

NP

Power part

The rectifier: 12-pulse diode bridge, consisting of two 6-pulse rectifiers in series.

The rectifier provides the DC voltage: DC+, DC- and the Neutral Point NP. The rectifier of each phase module (INU1, INU2, INU3) is supplied by two secondaries, 30°phase shift, but the overall phase shift between the six secondaries is 10°.

The DC link, equipped with DC link capacitors and Grounding Switch (not figured out here).

The inverter: H-bridge inverter (consisting of two 3-level inverter cells), equipped with four IGCTs (Integrated Gate Commutated Thyristor) with reverse conducting diodes integrated, and two Neutral Point diodes.

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-ACS 5000 main circuit diagram

Phase module W(=INU 3)

Phase module V(=INU 2)

Phase module U(=INU 1)

MRM

L_P1

L_N1

L_P

L_N

MRM

L_P1

L_N1

L_P

L_N

MRM

L_P1

L_N1

L_P

L_N

Power part

� Three separated DC links

� 12-pulse diode bridge per DC link

� Quasi 36-pulse (here: 2x18-pulse transformer topology)

-20°

0°

+20°

-20°

0°

+20°

diode bridgephase 3

diode bridgephase 1

diode bridgephase 2

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-ACS 5000 Air Cooled

Modularity: � 3.5 MVA single drive� 7 MVA single drive (double size CBU)

(=INU3)

(=INU2)

(=INU1)

(=COU/TEU) (=CBU)

Power part

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-Phase module

Rectifier stack

Grounding switch

Inverter stack

IGCT Power Supply (IPS)

Power part

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-Phase module (rear side)

RectifierInverter

Output CT

di/dt+

du/dt Filter Coil

Clamping resistors

Clamping resistors

du/dt Filter Resistor

Power part

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-Diode rectifier

� Rectifier consists of three 12-pulse diode bridges forming a 36-pulse system.

� The rectifier rectifies the AC line voltage and supplies electrical energy to the DC link capacitors.

Power part

Rectifier

1L11L21L3

2L12L22L3

DC+

NP

DC-

� The input rectifier bridges provide DC voltage and current to the DC link.

� They are wired in series such that their voltages are additive.

� All DC bus current flows through both bridges due to the series connection.

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-Charging

� The three DC links are charged via one common LV charging relay and one common charging transformer.

� Each DC link has got own HV charging relay.

� Charging of the DC links is done in parallel at the same time.

u1

v1

w1

u2

v2

w2

n2

DC (NP1)HV Relay

HV Relay

HV RelayDC (NP3)

DC (NP2)

Common rail (INU)

3ph Charging Transformer

LV Relay

-K1091

-K1092

-K1093

+A13 -Q1002

LV Relay

DC(NP1)

DC(NP2)

DC(NP3)

Common Rail

+A15 -T1091charging transformer

+A15

Power part

-T1091

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-Charging sequence

MIN

MAX

Val

ues

DC VOLTAGE

MCB order close

5000 VDC

5400 VDC

DC bus charging sequence � 20 s

Time (s)

Power part

Charging sequence:

� At the beginning Main Circuit Breaker (MCB) is off (drive status: RDY ON).

� Pre-charging the DC link (capacitors) is done by using charging circuit (charging transformer). The capacitors are charged before the converter is connected to the main power source to avoid excessive inrush currents (drive status: Charging).

� The voltage of the DC link will rise to a defined limit (“DC charging level”: 5000 V). At this limit the HV relay will be opened.

� “MCB closing level” (should be at least 100 V less than value “DC charging level”) => MCB closing is enabled.

� MCB is on and DC voltage reaches its nominal level.

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-Discharging

� In ACS 5000 Air Cooled the discharging can be done either with balancing resistors or with optional BCU (Braking Chopper Unit).

� When the DC link voltage reaches 1000 V, the drive performs a firing through to discharge the DC link quicker.

Power part

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-Grounding switch

� In ACS 5000 there are three separate DC links. Each DC link has its own grounding switch. Each grounding switch has three knives.

� Power part cabinet doors are interlocked with the safety grounding switch.

-Q7271

DC+

DC-

NP

L_P

L_N

M

PE

-Q7271

-Q7271

-Q7271

Power part

Because in ACS 5000 there are three physical GND switches, there are in total three feedback signals available from the GND switches. This means three “GND switch closed” and three “GND switch open” status signals.

GND switch status signals are connected in series both for the open and closed status. Drive status “GND switch closed” is reached only if all three GND switches are closed. Drive status “GND switch open” is reached only if all three GND switches are open.

If trying to ground the drive, all three GND switches need to be closed before drive is physically grounded. If one or two of the GND switches are not closed, “drive grounded” status will not be reached.

If trying to open the closed GND switches, all three switches need to be opened before “drive not grounded” status will be reached. If only one or two GND switches are opened, application SW will be in “DCGroundunknown” status.

GND switch 1 GND switch 2 GND switch 3 Drive grounding status0 0 0 not grounded1 0 0 unknown0 1 0 unknown0 0 1 unknown1 1 0 unknown1 0 1 unknown0 1 1 unknown1 1 1 grounded

GND switch open = 0GND switch closed = 1

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-Hard coupled DC link

� Directly connected to the DC bus bars.

� The hard and soft coupled DC link smoothes the intermediate DC voltage and decouples the rectifier from inverter.

� Hard and soft coupled capacitor bank are located in the right side of each phase module.

-C72

501/

U-C

7250

2/U

Power part

C72501

C72502

U U

D D

Hard and soft coupled capacitors

Rectifier / inverter stack

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-Inverter phase module (H-bridge)

� The inverter unit inverts the DC voltage to the AC motor voltage.

� The inverter allows four-quadrant operation.

� It is a 5-level Voltage Source Inverter.

� One inverter unit for each phase:

� One 3-level inverter cell to each motor phase

� One 3-level inverter cell to a Common Rail CR (star point) of all phases

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2 x 3-level inverter cells (H-bridge)

Power part

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To the motor phase (MPh)

To the star point / common rail (CR)

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-Inverter phase module

NP diode

Clamping diode

RC-IGCT

Clampingcapacitor

Balancing resistor

Power part

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-Integrated Gate Commutated Thyristor

� INU IGCTs free wheeling diode is integrated with RC-IGCT

Power part

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-Inverter operation: 3-level inverter cell

Output (CR or motor phase)

2

1

3

4

NPD1

NPD2

DC(+)

DC(-)

NP

-

0

+

NPD1+2 or

3+NPD2

NP2 + 3

3+4DC-3 + 4

1+2DC+1 + 2

Current path:„Output“connected to

IGCTs „ON“

Two IGCTs are turned „ON“ at a time:

VDC

Power part

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-Inverter operation: 5-level switching topology

V22

V23

V24

V12

V11

V13

V14

DC(+)

DC(-)

NP

CR(Inverter star point)

Motor phaseoutput

NP

V21

CR MPhVDC

VDC

2

VDC

2

Power part

-VDC/2+0

VDC

-VDC/2

+VDC

+VDC/2

+VDC/2

0

0

0

VMPh-C

VMPh-CR

-2+-

-10-

+2-+

-0

+10+

--

++0

00

VectorsCRMPh

Voltage levels

Phase to CR voltages:

Please note the redundancy for:

� vectors 0 (three combinations)

� +1 and -1 (two combinations)

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-Inverter operation: 9-level output to the motor

VDC

VDC

2

VDC

VDC

2

VDC

2

VDC

2

CR

L1

L2

VL1-L2 = VL1-CR + VCR-L2VL1-L2 = VL1-CR – VL2-CR

Power part

Combining the 5 levels for motor phase and CR for each phase, phase to phase voltages will have the values:

Note: Switching vectors L1 and L2 as in the previous page.

With, of course, a lot of redundancies:

(+2)&(-1) == (+1)&(-2), (+2)&(0) == (+1)&(-1) == (0)&(-2), etc.

-2 x VDCVDC+2-VDC-2

-3/2 x VDC-1/2 x VDC-1-VDC-2

-VDC00-VDC-2

-1/2 x VDC00-1/2 x VDC-1

00000

1/2 x VDC001/2 x VDC+1

VDC00VDC+2

3/2 x VDC-1/2 x VDC-1VDC+2

2 x VDC-VDC-2VDC+2

L1 - L2L2-CRL2L1-CRL1

Voltage VoltageVector Voltage Vector

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-Output wave forms

Torque

Line to line voltage

Current

Power part

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-How to reach the 6.9 kV

� Creating one line to line motor voltage

Power part

MOTOR

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-How to reach the 6.9 kVPower part

Current flow according to principle above:

MOTOR

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-How to reach the 6.9 kVPower part

Current flow according to principle above:

MOTOR

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-How to reach the 6.9 kVPower part

Current flow according to principle above:

MOTOR

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-How to reach the 6.9 kVPower part

Current flow according to principle above:

MOTOR

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-How to reach the 6.9 kVPower part

Current flow according to principle above:

MOTOR

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-How to reach the 6.9 kV

motor line to line voltage

time

10000 V

5000 V

-5000 V

-10000 V

� The line to line voltage at basic switching

Power part

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-Output voltage waveformsPower part

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-Output current waveformsPower part

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-Control HW in the phase module

VLSCD

VLSCD

Phase INT boardPEC-INT board

DC

AC

EAF

AC

DC

=INU 1_3

=COU

AMC board

HVD

CVMI

To next phase INT board

To next phase INT board

IPS IPS

Power part

The main control equipment is installed in the Control Cabinet (control boards AMC33 / AMC34, main modulator PEC-INT, I/O modules, etc.)

The main modulator PEC-INT is the interface between the control board (AMC3x) and the three phase interface boards INT, one in each phase module.

Control and protection boards are also installed in each phase module

� Phase Interface board INT

� Current and Voltage Measuring Interface CVMI

� High Voltage Divider HVD

� Earth Fault board, EAF, used as diode failure detection equipment

Note: A fourth EAF board is located in the Terminal Unit (TEU), behindthe swing frame of the control cabinet. This board is used for ground fault monitoring.

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-Control HW

INT CVMIEAF(as „diode failure

detection“)

Voltagesub-print

HVD

+A21

+A22

+A23

Power part

COU / TEU Phase modules

EAF as diode failure detection -A7221 in +A21 - +A23EAF, ground fault monitoring

-A9001, in +A15

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-Interface board (INT)

� 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.

Power part

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-Interface board (INT)

Aux power supply

RC-IGCT firing

FT link

PEC-INT communication

CVMI communication

FT-Loop (DC+)FT-Loop (DC-)

PWF IPS1 PWF IPS2

IOC from CVMI

VLSCD (DC+)VLSCD (DC-)

Link_A

Link_B

Link_C

Link_DPPCS Channels:

Power part

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-Interface board (INT)

2 green LEDs (V103, V113) for „POWER OK“. If they are on, the internal +5V DC supply voltages are within the allowed limits.

1 yellow LED „CONFIG. FAULT“near the EPLD circuit. LED is on during EPLD configuration

8 yellow LEDs (V561…V568) for testing the firmware in EPLD (firmware specific)

� INT board diagnostics: Indication LEDs

Power part

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-Short circuit detection

� In parallel to every INU di/dt choke a Voltage Level Short Circuit Detection(VLSCD) board is installed. The VLSCD board is a passive board, which detects the voltage appearing across the di/dt chokes during the commutation of the IGCTs. During this time a fiber optic signal is sent to control (Phase INT board).

AC

DC

+DC

NP

-DC

PHASE

VLSCD

VLSCD

VLSCD

VLSCD

+DC

-DC

NPPhase

di/dt+ di/dt-

VLSCD

INTnext phase

Phase INT

Power part

VLSCD is a pure analogue device which performs short circuit detection through the supervision of the voltage on the di/dt chokes (Ls1, Ls2).

� Each time when one of the IGCTs of the upper side is turned on there is a voltage on the Vls1 choke equal to the positive DC bus voltageduring the commutation time and each time when one of the IGCTs of the lower side is turned on there is a voltage on the Vls2 choke equal to the negative DC bus voltage during the commutation time.

� If this voltage remains more than a certain allowable time (6 – 10 µs), a short circuit has occurred. The supervision of this signal is made in the INT board and the supervision time is programmed in the EPLD.

� If signal does not appear every 50 ms, when inverter operates with sufficient load current

� VLSCD fault detection

� Optical output signal lights more or less at the same frequency as inverter switching frequency.

VLSCD is connected to high voltage!

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-Rectifier supervision / EAF board

� If measured voltage is above defined limit, the optical output signal of EAF board turns OFF and the PEC-INT board in COU detects a rectifier diode failure.

Power part

The only setting element on the board is the DIL switch. The selectable detection levels are (the voltage over Rn):

Check right settings from project related electrical diagrams.

1 2 3 4OFF OFF OFF ON ± 500 VOFF OFF ON OFF ± 660 VOFF ON OFF OFF ± 825 VON OFF OFF OFF ± 1150 V

Switch setting Switching threshold

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-Cooling

� The air cooling unit feeds the cooling air to the main power components and transfers the heat out of the cubicle.

� Standard converter cooling fan:

� 3.5 MVA – 2 fans

� 7.0 MVA – 3 fans

Power part

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-Cooling fan control

� The converter activates the cooling fans when charging the DC link. After a certain delay it begins to sample the air supervision. After a MCB off command the cooling fans run for a defined cooling down time.

Power part

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