ACS 6000 Medium voltage AC drives for control of 3 – 27 MW motors up to 3.3 kV

　　The ACS 6000 medium voltage drive for speed and torque control of 3 – 27 MW induction or synchronous motors is a member of the ABB AC drives product family. It offers a number of unique key features.

　　Powerful performance

　　Fast and accurate process control in combination with low energy consumption results in top performance. The motor control platform of the ACS 6000 is based on ABB’s award-winning Direct Torque Control (DTC) technology. DTC provides the highest torque and speed performance ever achieved in medium voltage drives. As a result, control of the drive is immediate and smooth under all conditions.

　　High efficiency and reliability

　　The ACS 6000 uses a revolutionary power semiconductor switching device known as IGCT (Integrated Gate Commutated Thyristor) researched and designed by ABB. The use of IGCTs results in a less complex, more efficient and reliable high-power medium voltage drive, minimizing operating and maintenance costs.

　　High availability

　　Maximum reliability and short repair time results in a drive with high availability.

　　Optimized energy flow

　　The common DC bus allows several motors to be connected to the same DC bus, providing an optimized energy flow.

　　The braking energy generated in one motor can be transferred to other inverters via the common DC bus without power consumption from the supply network. Due to the near unity power factor throughout the whole speed range the energy efficiency is optimal.

　　Power Electronic Building Block (PEBB), one phase leg of a three-level Voltage Source Inverter (VSI) topology to be configured to act as an AC to DC or DC to AC converter

　　Line Supply Unit (LSU) 6- or 12-pulse diode rectifier unit

　　Terminal Unit (TEU) and Control Unit (COU) Contains the power terminals and the control swing frame

　　Inverter Unit (INU) Self-commutated, 6-pulse, 3-level voltage source inverter with IGCT technology

　　Capacitor Bank Unit (CBU) DC capacitors for smoothing the intermediate DC voltage

　　Water Cooling Unit (WCU) Supplies the cooling system with deionized water for the main power components in LSU, INU and CBU

　　Technology highlights

　　Reliability has been the main guiding principle of the research and development activities for ABB’s medium voltage AC drives.

　　Part count

　　The fewer the parts the higher the reliability. ABB uses high power semiconductor switching devices and a topology that brings down the part count to a minimum. This results in a reliable, compact and service-friendly drive.

　　Fuseless design

　　The ACS 6000 medium voltage drive is designed to operate safely without fuses, resulting in less spare parts and better overall reliability. This allows fast startup after safety interruptions.

　　Encoderless

　　Encoders are known to cause failures due to their exposed position on the motor. ABB’s ACS 6000 medium voltage drive can operate without encoder, thereby reducing maintenance costs and ensuring high levels of availability

　　IGCT switching devices

　　ABB has developed a high power semiconductor called IGCT (Integrated Gate Commutated Thyristor) to allow the use of modern control algorithms, which can eliminate harmonics, improve dynamic response time and maintain, or even control, the power factor.

　　Low losses

　　The inherently low total losses of the IGCT require low cooling capacity and small cooling equipment.

　　Control

　　The ACS drive control platform is based on ABB’s award-winning Direct Torque Control (DTC), resulting in the highest torque and speed performance as well as lowest losses ever achieved in medium voltage drives. Control of the drive is immediate and smooth under all conditions and the audible noise in the motor is considerably reduced.

　　What is Direct Torque Control?

　　DTC is a revolutionary motor control method for AC drives that allows accurate control of both motor speed and torque without pulse encoder feedback from the motor shaft. 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. DTC ensures the absolute lowest losses by switching the power semiconductors only when necessary.

　　Fast response to mains fluctuations and process side changes

　　The exceptionally fast torque step response of the ACS 6000 means that it can respond to process and mains changes extremely fast. This enables easy handling of power-loss situations and sudden load changes.

　　Common DC bus

　　The ACS 6000 modularity is based on the common DC bus converter principle, where several motors (synchronous and induction) can be connected to the same DC bus. With five sizes of inverter modules available (3, 5, 7, 9 and 11 MVA), the optimum configuration for a specific application can be reached by combining the modules with minimum engineering effort. By linking the modules in parallel, the power can be increased to 27 MVA.

　　Multidrive topologies with a common DC bus offer a solution with optimum efficiency. Energy regenerated from one section in braking mode can be directly used by another section via the DC bus without power consumption from the supply network.

　　ACS 6000 modules

　　Active Rectifier Unit (ARU) , Inverter Unit (INU)

　　The Active Rectifier Unit (ARU) rectifies the AC line voltage and charges the DC link capacitors whereas the Inverter Unit (INU) inverts the DC voltage to the AC motor voltage.

　　The layout and equipment of the INU and the ARU are identical. They are self-commutated, 6-pulse, 3-level voltage source inverters, incorporating IGCT technology for a reliable, fuseless operation with a minimum number of drive components.

　　The ARU allows four-quadrant operation for regenerative braking, which reduces the overall energy consumption. It controls the power factor to unity in the whole operating range even at very low speeds. Optionally the ARU can be dimensioned to compensate reactive power generated by other loads connected to the same network.

　　Line Supply Unit (LSU)

　　The Line Supply Unit (LSU), designed for two-quadrant operation, maintains the power factor at 0.96 in the whole operating range.

　　Typically, the LSU is used for applications which only require two-quadrant operation. If short-term braking capability is needed, a Resistor Braking Unit with internal or external resistors can be installed.

　　Modular use, one design

　　The ACS 6000 is based on a modular product platform, expanding in line with customer’s requirements.

　　The ACS 6000 is designed as a set of modules. The modules are arranged according to the required output power, motor configuration and process needs.

product-data-sheet-ams-6300-sis-ams-en-105046.pdf

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