IEEE-ICIT 2010 CHILE A New Medium Voltage Drive System Based on ANPC-5L Technology

Transcription

1 Michael Basler, ABB Switzerland Ltd, March 2010 IEEE-ICIT 2010 CHILE A New Medium Voltage Drive System Based on ANPC-5L Technology March 16, 2010 Slide 1

2 Overview A new medium voltage drive system The ANPC-5L topology Converter configurations System integration Converter design March 16, 2010 Slide 2

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 IGBT topology Air cooled Suitable for standard motors and input isolation transformers March 16, 2010 Slide 3

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 March 16, 2010 Slide 4

5 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 MVdrives 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 March 16, 2010 Slide 5

6 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 ¼ of the total DC-link voltage To provide an additional level in the output voltages To have equally spaced steps in the output voltage March 16, 2010 Slide 6

7 From 3-level to 5-level topology 3-Level NPC VSI (ACS 1000 or ACS 6000) +V DC NP PH -V DC March 16, 2010 Slide 7

8 From 3-level to 5-level topology 3-Level NPC VSI Phase output voltages V PH +V DC NP -V DC March 16, 2010 Slide 8

9 From 3-level to 5-level topology 3-Level NPC VSI Phase output voltages V PH +V DC NP -V DC March 16, 2010 Slide 9

10 From 3-level to 5-level topology 3-Level NPC VSI Phase output voltages V PH +V DC NP -V DC March 16, 2010 Slide 10

11 From 3-level to 5-level topology From 3 levels to 5 levels: +V DC NP PH -V DC March 16, 2010 Slide 11

12 From 3-level to 5-level topology From 3 levels to 5 levels: 1. Replacing IGCTs with IGBTs +V DC NP PH -V DC March 16, 2010 Slide 12

13 From 3-level to 5-level topology From 3 levels to 5 levels: 1. Replacing IGCTs with IGBTs 2. Adding the Phase Capacitor Charged to ¼ of the total DC-link voltage +V DC NP V dc /2 PH -V DC March 16, 2010 Slide 13

14 Phase to ground voltage levels 5-Level ANPC VSI Phase output voltages V PH +V DC +V DC /2 NP -V DC /2 -V DC March 16, 2010 Slide 14

15 Phase to ground voltage levels 5-Level ANPC VSI Phase output voltages V PH +V DC +V DC /2 NP -V DC /2 -V DC March 16, 2010 Slide 15

16 Phase to ground voltage levels 5-Level ANPC VSI Phase output voltages V PH +V DC +V DC /2 NP -V DC /2 -V DC March 16, 2010 Slide 16

17 Phase to ground voltage levels 5-Level ANPC VSI Phase output voltages V PH +V DC +V DC /2 NP -V DC /2 -V DC March 16, 2010 Slide 17

18 Phase to ground voltage levels 5-Level ANPC VSI Phase output voltages V PH +V DC +V DC /2 NP -V DC /2 -V DC March 16, 2010 Slide 18

19 Phase to phase voltage levels March 16, 2010 Slide 19

20 Phase to phase voltage levels March 16, 2010 Slide 20

21 Phase to phase voltage levels March 16, 2010 Slide 21

22 Phase to phase voltage levels March 16, 2010 Slide 22

23 Phase to phase voltage levels March 16, 2010 Slide 23

24 Phase to phase voltage levels The switching vectors are symmetrical for the negative side of the waveform. March 16, 2010 Slide 24

25 Phase to phase voltage levels 15 Converter phase to phase voltage 10 5 voltage (kv) time(s) March 16, 2010 Slide 25

26 Controlling the phase capacitor voltage +V DC V6 Some vectors produce the same output voltage V5 and V6 produce +V CD /2 NP V dc /2 PH V1 and V2 produce -V CD /2 -V DC Redundant vectors are used to control the voltage level of the phase capacitor V5 Current direction changes in phase capacitor March 16, 2010 Slide 26

27 Network side Active Front End (AFE) with Input Filter Unit (IFU), di/dt clamp and DC-link capacitors March 16, 2010 Slide 27

28 Motor side Inverter unit (INU) with di/dt clamp and output filter for du/dt limitation March 16, 2010 Slide 28

29 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 March 16, 2010 Slide 29

30 Converter Configurations Connection to external transformer March 16, 2010 Slide 30

31 Converter Configurations Direct-to-line connection March 16, 2010 Slide 31

32 Converter Configurations Direct-to-line connection Main Power Supply Auxiliary Power Supply MCB (Standard) Close Open Trip Control UPS Power Supply Auxiliaries ACS 2000 Control Unit Power Part Motor IM March 16, 2010 Slide 32

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 Line side Controls Cooling no special motor required meet common network standards only simple input breaker needed HW level flexible I/O s SW level common ABB profile Simple integration possible March 16, 2010 Slide 33

34 System Integration Drive system configurations Main power supply Main circuit breaker Transformer ACS 2000 Motor M M M M M March 16, 2010 Slide 34 Classic configuration with external transformer Direct-to-line (DTL) connection Several direct-to-line drives on a common AC bus

35 Converter Design ACS 2000 converter Cooling fan Control unit Inverter Phase Modules Active front end (AFE) Phase Modules Cable entry March 16, 2010 Slide 35

36 Converter Design Cabinet front Phase modules Control unit DC-link Terminal field Input filter choke March 16, 2010 Slide 36

37 Converter Design Cabinet back Output filter choke DC busbar with di/dt clamp Filter resistors Input filter choke March 16, 2010 Slide 37

38 Converter Design Phase module Connectors Phase interface control board Phase capacitor March 16, 2010 Slide 38

39 Converter Design Phase module Phase capacitor Gate units Low inductive busbar Integrated current sensor IGBT modules Heatsink March 16, 2010 Slide 39

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 March 16, 2010 Slide 40

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 launch 1st wave UK, SE, ES, IT, CZ, PL Q2, nd wave Rest of Europe Q3, rd wave NAS & SAS Q1, th 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 March 16, 2010 Slide 41 A New Medium Voltage Drive System Based on ANPC- 5L Technology (VF ), Frederick Kieferndorf

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