ABB Group March 16, 2010 | Slide 1
IEEE-ICIT 2010 CHILE 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 standardapplications
Voltage source inverter
Medium voltage 66.9kV
Low power (400 kVA 1000 kVA)
Compact size
Multilevel IGBT 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 VSI 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 VSI topology (from ABB CRC)
Dual switch HV IGBT 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 VSI
Main differences to 3-level VSI 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 VSI (ACS 1000 or ACS 6000)
+VDC
NP
-VDC
PH
ABB Group March 16, 2010 | Slide 8
The ANPC-5L Topology From 3-level to 5-level topology
3-Level NPC VSI
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 VSI
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 VSI
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:
+VDC
NP
-VDC
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:
+VDC
NP
-VDC
PH
1. Replacing IGCTs with IGBTs
ABB Group March 16, 2010 | Slide 13
The ANPC-5L Topology From 3-level to 5-level topology
From 3 levels to 5 levels:
Vdc/2
+VDC
NP
-VDC
PH
1. Replacing IGCTs with IGBTs2. 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 VSI
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 VSI
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 VSI
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 VSI
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 VSI
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 ol 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 +VCD/2
V1 and V2 produce -VCD/2
Redundant vectors are used to control the voltage level of the phase capacitor
Current direction changes in phase capacitorV5
V6
ABB Group March 16, 2010 | Slide 27
The ANPC-5L Topology Network side
Active Front End (AFE) with Input Filter Unit (IFU), di/dt clamp and DC-link capacitors
+++
+
+
ABB Group March 16, 2010 | Slide 28
The ANPC-5L Topology Motor side
Inverter unit (INU) with di/dt clamp and output filter for du/dtlimitation
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
If a gate-emitter voltage is applied during on-state (saturation of IGBT) 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 IGBTs) is initiated.
Eliminates the possibility of IGBT 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 UnitControl
UPS Power Supply
Auxiliary Power Supply
MCB (Standard)CloseOpenTrip
Main Power Supply
Motor
IM
Auxiliaries
Power Part
ACS 2000
ABB Group March 16, 2010 | Slide 33
System Integration 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 I/Os
SW level common ABB profile Cooling Simple integration possible
ABB Group March 16, 2010 | Slide 34
System Integration Drive system configurationsMain power supply
M
Main circuit breaker
Transformer
ACS 2000
Motor
Classic configuration with
external transformer
M
Direct-to-line (DTL)
connection
M MM
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
Inverter 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
Input filter choke
ABB Group March 16, 2010 | Slide 37
Converter Design Cabinet back
Output filter choke
DC busbar with di/dt clamp
Filter resistors
Input 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
IGBT modules
Gate units
Heatsink
Integrated 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
Introduction in waves to ensure smooth market introduction
Stages Countries Internal launch1st wave UK, SE, ES, IT, 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
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