ACS6000 Technical Catalog

ACS 6000
Medium Voltage Drives

3 to 27 MVA
For Speed and Torque Control of
Synchronous and Asynchronous Motors
Technical Catalog
Document No.: 3BHS132322 ZAB E01, Rev. B
Effective: February 2003
 ABB Switzerland Ltd. All Rights Reserved.

ABB reserves all rights to this document, also in the event of patent issue
or registration of any other industrial property protection right. Misuse, in
particular duplication and forwarding to third parties, is not permitted.
This document has been checked with due care and attention. However,
should the user find any errors, these should be reported to ABB.
ABB aims to maintain the most modern standard, therefore, entries in this
manual may differ from the actual product.
ACS 6000 Technical Catalog

Table of Contents
Chapter 1 - Overview 13
1.1 Introduction 13
1.2 Field of Application 14
1.3 Modular Design 14
1.4 Key Technology 16
1.5 Benefits 17
1.6 CE Marking 19
Chapter 2 - Types and Applications 21
2.1 General 21
2.2 The ACS 6000 Drive Types 21
2.2.1 Single-motor Drives 21
2.2.2 Multi-motor Drive 23
2.2.3 Redundant Configurations 24
2.2.4 Twin Configuration 25
2.3 Application Examples 25
2.3.1 Marine Propulsion and Thruster Drives 25
2.3.2 Rolling Mill Applications 29
2.3.3 Mining Applications 33
Chapter 3 - Key Technologies 37
3.1 General 37
3.2 Direct Torque Control 37
3.2.1 DTC Principle 37
3.2.2 DTC Performance 38
3.3 IGCT Power Semiconductors 40
3.4 Active Rectifier Unit 41
3.4.1 Operating Principle 41
3.4.2 Control Principle 42
3.4.3 Power Factor Control 43
3.4.4 Optimized Pulse Patterns 43
3.4.5 Control Block Diagram 44
3.5 Line Supply Unit 44
3.6 Common DC Bus 45
3.6.1 Principle 45
3.6.2 Advantages 45
ACS 6000 Technical Catalog 1 / 166

Chapter 4 - Converter Configuration and Hardware 47
4.1 Overview 47
4.2 Modular Concept 47
4.3 Configuration Guidelines 49
4.3.1 Required Application Data 49
4.3.2 Configuration Procedure 49
4.3.3 Configuration Rules 49
4.4 Cabinet Design 50
4.4.1 Mechanical Design 50
4.4.2 Electromagnetic Compatibility (EMC) 50
4.4.3 Safety Aspects 51
4.5 Busbars and Grounding 51
4.6 Auxiliary Supply System 52
4.6.1 AC Safe Line 52
4.6.2 DC Safe Line 53
4.6.3 No Safe Line 54
4.7 Cooling System 55
Chapter 5 - Description of Modules 57
5.1 Overview 57
5.2 Line Supply Unit (LSU) 57
5.2.1 Overview 57
5.2.2 Main Components 58
5.2.3 Circuit Diagram 58
5.2.4 Types and Sizes 59
5.3 Active Rectifier Unit (ARU) 59
5.3.1 Overview 59
5.4 Inverter Unit (INU) 62
5.4.1 Overview 62
5.5 Capacitor Bank Unit (CBU) 63
5.5.1 Overview 63
5.6 Terminal Unit (TEU) 66
5.6.1 Overview 66
5.6.2 Types 66
2 / 166 ACS 6000 Technical Catalog

5.7 Control Unit (COU) 67
5.7.1 Overview 67
5.7.3 Types 68
5.8 Water Cooling Unit (WCU) 69
5.8.1 Overview 69
5.8.3 Water Cooling Circuit 71
5.8.4 Cooling Control 73
5.9 Customer Interface Unit (CIU) 74
5.9.1 Overview 74
5.9.3 Overview Drawing 75
5.10 Input Filter Unit (IFU) 76
5.10.1 Overview 76
5.11 Voltage Limiter Unit (VLU) 77
5.11.1 Overview 77
5.12 Resistor Braking Unit (RBU) 79
5.12.1 Overview 79
5.13 Braking Chopper Unit (BCU) 81
5.13.1 Overview 81
5.14 Isolator Unit (ISU) 83
5.14.1 Overview 83
5.15 Excitation Unit (EXU) 83
5.15.1 Overview 83
5.15.2 Excitation Circuit 84

Chapter 6 - Control System and Process Interfaces 87
6.1 Control Hardware Concept 87

6.1.1 Overall Control Structure 87
6.1.2 AMC3 Controller 88
6.1.3 Control Hardware Topologies 89
6.2 Software Concept 91
6.2.1 Control Software Structure 91
6.2.2 Operating System 92
6.2.3 Motor and Rectifier Control Software 92
6.2.4 General Fault Handler 92
6.2.5 Main State Machine 93
6.2.6 Application Program 93
6.3 User Interfaces 93
6.3.1 CDP 312 Control Panel 93
6.3.2 Pushbuttons and Pilot Lamps 95
6.3.3 PC-Tools 95
6.4 Start and Stop Sequences 96
6.4.1 Local and Remote Control 96
6.4.2 Start Sequence 97
6.4.3 Stop Sequence 98
6.4.4 Emergency Off Sequence 100
6.5 Interface Configurations 100
6.5.1 General 100
6.5.2 I/O Configurations for Single-motor Drives 100
6.5.3 I/O Configurations for Multi-motor Drives 101
6.6 Fieldbus Interfaces 103
6.6.1 Fieldbus Types 103
6.6.2 Signals 103
6.7 Hardwired Process I/Os 106
6.7.1 S800 I/O Modules 106
6.7.2 Signals 109
6.7.3 Standard Signals 109
6.7.4 I/O with CIW 1 Option (Standard Software) 111
6.7.5 I/O with CIW 2 Option (Project Specific SW) Controlled
by AC80 Controller 113
Chapter 7 - Standard Control and Protection Functions 115
7.1 General 115

7.2 Motor Control Functions 115
7.2.1 Speed Control Features 115
7.2.2 Direct Torque Control Features 116
7.3 Active Rectifier Control Functions 117

7.4 Application Control Functions 117
7.4.1 Motor Related Functions 117
7.4.2 Network Related Functions 117
7.5 Diagnostics 119
7.6 Standard Protection Functions 119
7.6.1 General 119
7.6.2 Internal Protection Functions 120
7.6.3 External Protection Functions 122
7.6.4 Manually Initiated Protection Functions 122
7.7 Other Features 123
7.8 Customer Specific Options 123
Chapter 8 - Options 125
8.1 Converter Hardware 125

8.2 Converter Software 126
8.3 Service and Diagnostics 127
8.4 Marine Version 128
8.5 Transportation, Installation and Commissioning 128
8.6 Training 128
8.7 Testing 128
8.8 Documentation 129
Chapter 9 - Requirements for System Components 131
9.1 General 131

9.2 Main Circuit Breaker 131
9.2.1 Maximum Breaking Time 131
9.2.2 Control Interface 131
9.2.3 Main Circuit Breaker Equipment 132
9.2.4 Main Circuit Breaker Connection Schemes 133
9.3 Main Transformer for ARU 134
9.3.1 Transformer Windings 135
9.3.2 Technical Data 135
9.4 Main Transformer for LSU 136
9.4.1 Transformer Windings 136
9.4.2 Technical Data 137
9.5 ARU Synchronization Transformer 137
9.5.1 Requirements for Synchronization Transformers 137
9.5.2 Two Possible Measurement Connections 137
9.6 Excitation Supply 138

9.7 Synchronous Motor Requirements 139
9.7.1 Windings 139
9.7.2 General Motor Characteristics 139
9.7.3 Encoders 140
9.7.4 Bearings 140
9.7.5 Excitation 140
9.8 Asynchronous Motor Requirements 140
9.8.1 Windings 140
9.8.2 General Motor Characteristics 141
9.8.3 Encoders 141
9.8.4 Bearings 141
9.9 Selection of Power Cables 141
9.9.1 Power Cable Dimensioning 141
9.9.2 Cables for ARU and INU 142
9.9.3 Cables for LSU 143
9.9.4 Cables for BCU 143
9.10 Control Cabling 143
Chapter 10 - Installation Guidelines 145
10.1 Space Requirements 145

10.2 Structural Requirements 146
10.3 Mechanical Installation 146
10.4 Power Cable Installation, Grounding and Shielding 147
10.4.1 Connecting ARU to Supply Transformer 148
10.4.2 Connecting LSU to Supply Transformer 149
10.4.3 Connecting Motor to INU 150
10.4.4 Equipment Grounding 151
Appendix A - Technical Data 153
Converter Output / Motor Connection 153

ARU Input 154
LSU Input 155
Auxiliary Supply 156
EXU Supply 156
Environmental Aspects 157
Derating of Drive Power 157
Transportation and Storage 157
Cooling 158
Converter Enclosure 159
Language 160

Appendix B - Applicable Codes and Standards 161
General 161
International Standards for Design and Construction 161
EMC Standards 162
Marine Standards for ACS 6000 Marine Drives 163
Appendix C - ACS 6000 Type Code 165
Type Code Limitations 166

List of Abbreviations
AC80 Advant Controller
AF100 Advant Fieldbus 100 (ABB Bus System)
AI Analog Input
AMC Application and Motor Controller
AMCOS Application and Motor Controller Operating System
AO Analog Output
ARU Active Rectifier Unit
ASE Anti Saturation Equipment
BCU Braking Chopper Unit
BOD Breakover Diode
CBU Capacitor Bank Unit
CCB Converter Controller Board
CDP 312 Control Panel
CHU Charging Unit
CIU Customer Interface Unit
CIW Customer Interface Unit (integrated into WCU)
COU Control Unit
CVMI Current and Voltage Measuring Interface Board
CWU Control Water Unit (control equipment inside WCU)
DC_NP DC Neutral Point
DDCS Distributed Drive Control System (communication

protocol)
DI Digital Input
DIU Discharging Unit
DO Digital Output
DTC Direct Torque Control
ECB Excitation Circuit Breaker
EMC Electromagnetic Compatibility

EXU Excitation Unit
FCB Function Chart Builder
FCI Fieldbus Communication Interface
FIR FILTER Finite Impulse Response Filter
FSCD Fast Short Circuit Detection Board
GCT Gate Commutated Thyristor
GDR Gate Driver Board
GTO Gate Turn-off Thyristor
GUSP Gate Unit Power Supply
HVD High Voltage Divider Board
IFU Input Filter Unit
IGBT Insulated Gate Bipolar Transistor
IGCT Integrated Gate Commutated Thyristor
IM Induction Motor
INT Interface Board
INU Inverter Unit
IRU Input Reactor Unit
ISU Isolator Unit
LSU Line Supply Unit
MCB Main Circuit Breaker
NTAC Pulse Encoder Interface Module
PAI Pulse Amplifier Interface Board
PE Protective Earth
PFF Power Feed Forward
PG Power Ground
PINT Pulse Interface
PPCS Power Plate Communication System (communica-

tion protocol)
PUB PPCS Unit for Branching

PWM Pulse Width Modulation
RBU Resistor Braking Unit
S800 Input / Output Board
SM Synchronous Motor
TEU Terminal Unit
UPS Uninterruptible Power Supply
VLU Voltage Limiter Unit
WCU Water Cooling Unit

Chapter 1 - Overview
1.1 Introduction
This Technical Catalog describes the main electrical, mechanical and

environmental features of the ACS 6000, the modular medium voltage
drive for megawatt class applications. It outlines the outstanding advan-
tages of the ACS 6000:
• Optimum performance
• High efficiency
• Unequalled availability
It illustrates, how the converter can be configured to achieve optimum
performance in the field of marine and industrial drive applications with
induction and synchronous motors. The catalog describes available
options for the converter and provides information to select the most suit-
able motor-converter combination. It also provides useful hints for the
installation.
Figure 1-1 ACS 6000, Typical Marine Configuration

1.2 Field of Application
The ACS 6000 provides the optimum solution for marine and industrial
medium voltage drive applications. The ACS 6000 variable speed drive
covers a power range from 3 to 27 MVA and delivers output frequencies
from 0 to 75 Hz (250 Hz in twin configurations). It is used in a wide range
of fields, such as:
Marine • Main propulsion systems

• Thruster drives
Oil and Gas • Compressors

• Pumps
Metals and Mining • Rolling mills

• Mine hoists
• Overland conveyors
• Crushers and mineral mills
General Industry • Variable speed fans and pumps

• Pump storage plant drives.
1.3 Modular Design
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.
Depending on the application, four different types of configurations are
available (Figure 1-2):
• Single-motor drive configurations
for synchronous or asynchronous motors
• Multi-motor drive configurations
for multiple synchronous or asynchronous motors or combinations of
both types
• Redundant drive configurations
for motors with two winding systems
• Twin configurations
for motors with winding systems supplied on both ends by the
converter

The following ACS 6000 modules are available:

• Line Supply Unit (LSU)
12-pulse diode rectifier
• Active Rectifier Unit (ARU)
6-pulse self commutated voltage source inverter
• Inverter Unit (INU)
6-pulse self commutated voltage source inverter
• Capacitor Bank Unit (CBU)
DC link capacitors
• Terminal Unit (TEU)
power cable termination section
• Control Unit (COU)
control system (always integrated into TEU)
• Water Cooling Unit (WCU)
• Customer Interface Unit (CIU)
additional I/Os
• Input Filter Unit (IFU)
harmonic filter for ARU to be used depending on supply network
configuration
• Voltage Limiter Unit (VLU)
dynamic DC voltage limiter
• Resistor Braking Unit (RBU)
DC chopper with integrated resistors
• Braking Chopper Unit (BCU)
DC chopper to be used in combination with external resistors
• Isolator Unit (ISU)
disconnector for 2 CBUs only used in redundant configurations
• Excitation Unit (EXU)
6-pulse thyristor bridge or AC power controller
Refer to the detailed description of each module in Chapter 5 - Description
of Modules for information on paralleling modules (e.g. 24-pulse rectifier).

TEU
LSU INU CBU WCU AC DC
COU
DC AC
M
Single Drive with Diode Rectifier
TEU TEU
ARU ARU CBU VLU INU TEU INU WCU EXU
COU COU
AC DC DC
AC
DC AC AC DC
Multi-drive with Active Rectifier M M
TEU TEU
LSU INU CBU LSU INU CBU WCU
COU COU AC DC DC
DC AC AC
M
Twin Drive with Diode Rectifier (planed solution)
TEU TEU
EXU WCU LSU INU RBU CBU ISU CBU RBU INU LSU WCU EXU
COU COU
AC DC DC AC
AC DC AC AC DC AC
DC DC
M
Redundant Drive with Diode Rectifier (planed solution)
Figure 1-2 Typical Examples for Basic Configurations
1.4 Key Technology
The following features distinguish the ACS 6000 from other converters on
the market:
DTC Direct Torque Control enables highest torque and speed control perfor-
mance ever achieved in medium voltage drives. DTC allows:
• Torque response times up to ten times faster than conventional
control methods using flux vector or pulse width modulation

• Minimal torque ripple

• Acccurate static speed and torque control
IGCT The Integrated Gate Commutated Thyristor is a power semiconductor

switching device specifically developed for medium voltage converters.
Based on well established GTO (Gate Turn Off Thyristor) technology, it
enables intrinsically less complex, more efficient and reliable converter
designs.
IGCTs combine high speed switching capabilities as known from IGBTs
(Insulated Gate Bipolar Transistors) with high blocking voltage and low
conduction losses as known from GTOs.
ARU The Active Rectifier Unit allows four-quadrant operation, thus regenerative
braking is possible in both rotating directions of the motor over the whole
power range.
The ARU controls the power factor to unity in the whole operating range
even at very low speeds. Optionally the ARU compensates reactive power
generated by other loads connected to the same network.
The ARU reduces and eliminates harmonics in the voltage applied to the
mains by using pre-defined, optimized pulse patterns.
LSU The Line Supply Unit designed for two-quadrant operation maintains the
power factor at 0.95 in the whole operating range.
Common DC Bus Multiple rectifiers and motor inverters can be connected to the same DC
bus. This allows to combine several drives into one converter unit.
Braking energy generated in one motor can be transferred to other
inverters via the common DC bus without loading the rectifier.
1.5 Benefits
Maximum Availability High reliability and short repair time result in maximum availability.
High reliability is achieved by:
• Proven technology:
The design of the IGCT used in ACS 6000 is based on well estab-
lished GTO technology. IGCTs have been used successfully in
medium voltage converters for more than 5 years.
• Low parts count:
The fast switching capability of the IGCT allows snubberless circuit
topologies. This results in a smaller number of power components
which improves the operational reliability.

• Fuseless design:
Avoiding the use of unreliable fuses results in better overall reliability.
Short repair time is achieved by:
• Diagnostics system:
A comprehensive self diagnostic monitoring system generates
concise error messages with information on error type and location.
This enables quick and precise localization of disturbances and
reduces time spent on fault finding.
• Simplicity of power circuit:
The simplicity of the power circuit and the modular design of the hard-
ware do not only lead to extremely high availability but also provide
the base for a maintenance and repair concept which is characterized
by minimum outage times, e.g. a complete phase module can be
exchanged in less than 1 hour.
Top Performance Fast and accurate process control in combination with low energy
consumption results in top performance.
Fast and accurate process control based on DTC results in high and
constant production quality, minimum raw material waste, and minimum
machinery wear. DTC guarantees:
• Highly dynamic response times without overshoot
• Accurate static speed and torque control
• Smooth output current waveforms resulting in minimum torque ripple.
Low energy costs are achieved by:
• Minimal reactive power consumption
The reactive power demand of the drive can be neglected by using
ARU or LSU . The supply system needs only to be designed for effec-
tive power consumption. Reactive power compensators are not
needed.
• Multi-drive topology
The common DC bus enables further energy savings with multi-motor
arrangements. Energy regenerated from one section in braking mode
can be used by other sections (directly via DC link). This is achieved
without loading supply transformers or the network.
• Four-quadrant operation
Drives equipped with ARU are suitable for regenerative braking. This
reduces the overall energy consumption in many applications.
Low Maintenance Cost Maintenance costs are minimized due to extended maintenance periods,
low number of maintenance tasks and maintenance on the running
system.

Extended maintenance periods and fewer maintenance tasks due to water

cooling:
• Easy wearing parts, such as fans and bearings needed in air-cooled
systems, are not used.
• No ventilation inlets are required. Dust cannot enter the system and
air filters are not needed.
Maintenance on running system:
• The maintenance or replacement of redundant cooling pumps can be
done on the running system.
What You Need is what Customer requirements are precisely met. The flexible design with stan-
You Get dard modules and the well proven control platform allow the optimum
configuration of any drive system.
Modular design:
• Converter rating fits exactly customer requirements.
• Each configuration consists of well proven and certified modules,
thus minimizing the risk of design errors.
• The compact, standardized design and the integrated water cooling
system reduce space requirements and have positive impacts on
room conditioning.
• Multi-drive topologies with common DC bus are possible.
In applications where parallel driving and braking is needed, the
ratings of converter transformers, breakers and cables can be
reduced.
• Installation and commissioning time is reduced compared to engi-

neered systems due to standardized procedures and documentation.
Well proven ABB AC drives control platform:
• Configurable application software and standard interfaces for hard-
wired I/Os allow optimum integration into the industrial environment.
• Interfaces for all common fieldbus types are available for communi-
cation with the overriding control system.
• Standardized control panels and operational tasks, common for all
ABB AC drives, allow a simple and user friendly operation.
1.6 CE Marking
The ACS 6000 frequency converter is marked with a CE symbol.The CE

marking indicates that the ACS 6000 complies with the basic technical
requirements and conformity valuation criteria and is an essential require-
ment of the relevant EC directives.


Chapter 2 - Types and Applications
2.1 General
The design of the ACS 6000 is characterized by its modular structure and
the common DC bus concept: Depending on the individual drive configu-
ration and the power demands of the process environment, multiple line
supply units or active rectifier units are connected together with motor
inverter modules to the same DC bus.
A number of typical applications from the marine and industrial field are
shown in this chapter. The examples illustrate how the modular concept of
the ACS 6000 is applied to provide the optimum converter configuration
for high power applications.
2.2 The ACS 6000 Drive Types
2.2.1 Single-motor Drives

Single-motor configurations are commonly used in applications which
require large and independent drives, such as:
• Main propulsion drives for shuttle tankers, cruisers and ferries
• Thruster drives for dynamic positioning of drilling vessels or floating
production vessels
• Mining and general industrial applications with large fans, pumps,
compressors, crushers or hoists
• Individual rolling mill stands.
Basic Configuration The basic configurations for single-motor applications of up to 9 MVA are
shown in Figure 2-1. The rectifier is connected to the input transformer
(line supply unit, a and c Figure 2-1, or active rectifier unit, b and d in
Figure 2-1) and the inverter unit is feeding the motor. For smoothing the
DC voltage, a capacitor bank unit is connected to the DC bus. In case of
a synchronous motor, an excitation unit is added to the configuration (see
bottom of Figure 2-1).
The terminal and control module and the water cooling module complete
the basic converter. A resistor braking unit and/or a voltage limiter unit are
optional.

Mains Mains
A B Synchronization voltage
Aux. power Aux. power
TEU TEU
LSU INU CBU WCU COU ARU INU CBU WCU COU
Aux. Aux.
AC DC
DC AC
Control Control
I/O I/O
CHU CHU
TEU TEU
M
IM IM
TEU TEU
LSU INU CBU WCU ARU INU CBU WCU
COU COU
Mains Mains
C D Synchronization voltage

Excitation power Excitation power
TEU TEU
LSU INU CBU WCU EXU COU ARU INU CBU WCU EXU COU
Aux. Aux.
AC DC
AC
DC AC DC Ctrl Ctrl
I/O I/O
CHU CHU
TEU TEU
M
SM SM
PG PG
T T
TEU TEU
LSU INU CBU WCU EXU ARU INU CBU WCU EXU
COU COU
Figure 2-1 Single-motor Drives, Basic Configurations

The figure above shows the basic configurations of the ACS 6000 for
induction motors (A,B) and synchronous motors (C,D).

Single Drives with For single drives of larger sizes, multiple power stages are used in parallel:
Multiple Units line supply units or active rectifier units on the supply side and two inverter
modules on the motor side, as shown in Figure 2-2.
Dimensions of capacitor bank unit and water cooling unit depend on the
rated converter power. Several module sizes are available.
Mains
Synchronization voltage
Aux. power
Excitation power
TEU TEU
ARU ARU CBU INU INU WCU EXU COU
Aux.
AC DC Ctrl
AC
DC AC DC
Control
I/O
TEU TEU
M
SM
PG
Aux. T
TEU TEU
ARU ARU CBU VLU INU INU WCU EXU
COU COU
Figure 2-2 Single-motor Drive, SD Type, Example with Active Rectifier

The figure above shows a typical example of a parallel configuration with
multiple units (9 – 18 MVA): two inverter modules and a 12-pulse supply
with two active rectifier units for a synchronous motor. Depending on the
application, other configurations with line supply unit and/or induction
motor are possible, e.g 24-pulse supply with two line supply units. The
VLU is optional.
2.2.2 Multi-motor Drive

Multi-drive configurations are used in applications where a set of individual
motors are combined into functional units, e.g. with combined driving and
braking needs, for example:
• Sendzimir mills, rolling mill trains and continuous strip production
lines
• Conveyor systems.
• Marine propulsion and thruster drives
• Drilling packages

• Pulp & Paper

Several motors of same or different sizes are fed from one common DC
bus (see examples in Figure 2-3, Figure 2-7 and following). Depending on
the type of rectifier, a maximum of 4 or 5 INUs can be connected (for
details see Chapter 4 - Converter Configuration and Hardware, Configu-
ration Guidelines, page 49).
Synchronous and induction motors can be mixed. A separate control unit
is required for each motor. Each synchronous motor needs an EXU.
Combining several motors of a process with one multi-drive converter, the
number of MCBs and transformers can be reduced.
In applications with parallel driving and braking, where only the net power
demand has to be drawn from the supply busbar, the ratings of the rectifier
module, main circuit breaker and transformer can be reduced substantially
(see case study of a Sendzimir mill in Table 2-1).
Mains

Synch. reference Excitation power
TEU TEU
COU ARU ARU CBU INU INU WCU EXU COU COU
AC DC DC Aux.
Aux. Aux.
AC
DC AC AC DC Ctrl
Control Control Control
I/O I/O I/O
TEU TEU
M M
SM
IM
PG
T T
TEU TEU
ARU ARU CBU VLU INU TEU INU WCU EXU
COU COU
Figure 2-3 Example of a Standard Multi-drive Configuration
2.2.3 Redundant Configurations

The ACS 6000 allows various schemes for redundant drive configurations.
Thus operation at reduced power is maintained in case of a partial failure
of the converter.
An example is given in Propulsion and Thruster for Shuttle and Service
Vessels, page 27. The configuration shows a standard drive for a 2 split,
redundant main propulsion system with a tandem motor for marine appli-

cations. The DC bus can be split with an isolation unit and the converter
modules are arranged symmetrically with two separate feeders.
2.2.4 Twin Configuration

Twin configurations are designed for motors with winding systems
supplied on both ends by the converter. This allows higher converter
output frequencies and double output voltage.
The planed solution of the ACS 6000Twin is illustrated in Figure 2-4.
Mains Mains
Aux. power
LSU CBU INU LSU CBU INU WCU COU
AC DC DC Aux.
DC AC AC
Control
I/O
IM
TEU TEU
LSU INU CBU LSU INU CBU WCU
COU COU
Figure 2-4 Example of Standard ACS 6000Twin Configuration (planned)
2.3 Application Examples
2.3.1 Marine Propulsion and Thruster Drives

Electric propulsion is widely used in today‘s marine technology. The
ACS 6000 with its modular concept is the perfect answer to the require-
ments of modern propulsion schemes for floating production facilities,
dynamically positioned drilling vessels, shuttle tankers, service ships and
for large passenger vessels.
The main reasons for choosing the ACS 6000 in marine applications are:
• Outstanding reliability
• Small footprint and weight of propulsion system

• High immunity to varying climatic conditions and vibrations

• High torque over entire speed range.
Dynamic Positioning of Figure 2-5 shows a typical example for a dynamically positioned offshore
Floating Vessels drilling rig. It is equipped with four ACS 6000 single drives.
Mains
Aux. power
G G TEU
LSU INU CBU WCU COU
Aux.
11 kV / 60 Hz 11 kV / 60 Hz Control
I/O
CH
U
TEU
Mains
IM
Aux. power
AC DC AC DC
DC AC DC AC
TEU
LSU INU CBU WCU COU
Aux.
M M
Control
CH I/O
U
TEU
3200 kW 3200 kW
740 RPM 740 RPM
IM
Mains
G G
Aux. power
11 kV / 60 Hz 11 kV / 60 Hz
TEU
LSU INU CBU WCU COU
Aux.
Control
CH I/O
U
TEU
AC DC AC DC
Mains
DC AC DC AC
IM
Aux. power
M M
TEU
LSU INU CBU WCU COU
3200 kW 3200 kW
Aux.
740 RPM 740 RPM
Control
CH I/O
U
TEU
IM
Figure 2-5 Example of System Configuration for Offshore Drilling Rig

Propulsion and Figure 2-6 shows an example of a redundant main propulsion system
Thruster for Shuttle and where the power system can be split. The main propeller (Azipod or
Service Vessels conventional installation with shaft) is driven by a variable speed tandem
motor fed by a redundant ACS 6000 converter. For positioning and
manoeuvring, 2 x 2 thrusters on common DC bus (Azipod and propeller
units) are provided.
Mains 11 kV / 60 Hz 11 kV / 60 Hz Mains

Excitation. power Excitation. power
TEU TEU
COU EXU WCU LSU INU CBU ISO CBU INU LSU WCU EXU COU
Aux. Aux.
Ctrl Ctrl
Control Control
I/O I/O
TEU TEU
Mains Mains
SM
TEU TEU
LSU CBU INU INU WCU COU COU LSU CBU INU INU WCU COU COU
Aux. Aux. Aux. Aux.
Control Control Control Control
I/O I/O I/O I/O
TEU TEU TEU TEU
IM IM IM IM
G G G G
AC DC DC AC AC AC DC DC
DC AC AC DC DC DC AC AC
M M DC DC M M
AC AC
1700 kW 3000 kW 1700 kW 3000 kW

750 RPM 750 RPM 750 RPM 750 RPM
M
12000 kW
90 RPM
Figure 2-6 Redundant Main Propulsion System

Main Propulsion with Figure 2-7 shows a typical configuration for a service vessel with two main
Azipod Thrusters propulsion Azipod thrusters assisted by two smaller (tunnel) thrusters.
This type of configuration is used in case of smaller power requirements.
An arrangement with two ACS 6000 multi-drives and line reactances
instead of transformers is the most feasible solution.
Mains Mains
TEU TEU
LSU CBU INU INU WCU COU COU LSU CBU INU INU WCU COU COU
Aux. Aux. Aux. Aux.
I/O I/O I/O I/O
TEU TEU TEU TEU
IM IM IM IM
G G G G
3.3 kV / 60 Hz 3.3 kV / 60 Hz
AC DC DC AC DC DC
DC AC AC DC AC AC
750 kW 5000 kW 5000 kW

750 RPM M 120 RPM M 120 RPM
M M
Figure 2-7 Configuration for a Service Vessel

2.3.2 Rolling Mill Applications

Metals applications are characterized by quickly changing loads, fast
changes between driving and braking operations, constant torque in a
wide speed range and large torque steps.
The main reasons for choosing the ACS 6000 in rolling mill applications
are:
• Fast and precise torque and speed control under varying loads
• Full 4 quadrant operation with active rectifier
• Reduced energy consumption with common DC bus concept.
Hot Rolling Mill Train The ACS 6000 with its modular concept is the perfect answer to the
requirements of the metals industry. This is illustrated in the following
examples.
M M
Edger mill Rougher mill Crop shear
M
M M
M
M M M
Reversing steckel mill
M M
M M M M M M
Hot tandem mill
M M M M M M M M
Figure 2-8 Hot Rolling Mill Train: Overview

Rougher Mill Train A typical rougher mill consisting of edger, rougher and crop shear is shown
in Figure 2-9. Edger and crop shear are equipped with relatively small
drives (crop shear with up to 300% overload capability). These drives can
be combined into one single ACS 6000 multi-drive scheme. Synchronous
and induction motors can be combined.
Two separate ACS 6000 single drives are used for the rougher mill stand.
Each of the two synchronous motors is equipped with two three-phase
winding systems.
Mains
Aux. power
Aux. power
Synch. Reference
Excitation power
TEU
COU ARU CBU INU INU INU INU WCU EXU EXU COU COU COU COU
Aux. Aux. Aux. Aux.

Aux.
Ctrl Ctrl
Control Control Control Control Control
I/O I/O I/O I/O I/O
TEU TEU TEU TEU
SM SM
IM IM
PG PG
T T PG PG
M
6 MW M
(250 %)
M
M M
M
6 MW 2x 900 kW
2 x 900 kW
(250 %) (300 %)
Mains Mains
Synchronization voltage Synchronization voltage
TEU TEU TEU TEU

ARU ARU CBU INU INU WCU EXU COU ARU ARU CBU INU INU WCU EXU COU
Aux. Aux.
Ctrl Ctrl
Control Control
I/O I/O
TEU TEU TEU TEU
SM SM
PG PG
T T
Figure 2-9 Rougher Mill Train

Reversing Steckel Mill A typical converter arrangement for a reversing steckel mill is shown in
Figure 2-10.
The drives for entry and exit coilers and the drive for the down coiler are
combined into one ACS 6000 multi-drive. The energy generated on the
decoiling side is transferred via the common DC bus to the other coiler
without loading the supply line. Therefore the net power demand is
reduced.
The two main mill drives with synchronous motors are equipped with
ACS 6000 single drives. In order to provide sufficient overload capabilities
two INUs are feeding each motor.
Mains
Synch.Reference
Aux. power
TEU TEU
COU ARU ARU CBU INU INU INU WCU COU COU COU
Aux. Aux. Aux.

Aux.

I/O I/O I/O I/O
TEU TEU TEU
IM IM IM
800 kW 800 kW
(225 %) (225 %)
M M
M
1200 kW
(200 %)
M
2 x 5 MW
M
(250 %)
Mains Mains
Synchronization voltage Synchronization voltage

TEU TEU TEU TEU

ARU ARU CBU INU INU WCU EXU COU ARU ARU CBU INU INU WCU EXU COU
Aux. Aux.
Ctrl Ctrl
Control Control
I/O I/O
TEU TEU TEU TEU
SM SM
PG PG
T T
Figure 2-10 Reversing Steckel Mill

Sendzimir Mill The sendzimir cold rolling mill consists of a mill stand and two tension reels
as shown in Figure 2-11. The whole system can be realized with one
ACS 6000 multi-drive.
The energy generated by the braking reel is transferred via the common
DC bus to the driving reel without loading the supply line. Therefore the
net power demand is reduced. The supply rating can be reduced by
almost 50% compared to a setup with individual drives (see Table 2-1).
Mains
Aux. power
Synch. Aux. power
Reference
Excitation power
COU ARU ARU CBU INU INU INU WCU EXU EXU EXU COU COU COU
Aux. Aux. Aux.

Aux.
Ctrl Ctrl Ctrl

I/O I/O I/O I/O
SM SM SM
PG PG PG
T T T
4.5 MW
(200 %)
M
4.5 MW
M
(200 %)
4.5 MW
M
(200 %)
Figure 2-11 Sendzimir Mill

Table 2-1 Case Study: Power Requirement of a Sendzimir Mill with

ACS 6000
Estimated Power Requirement Converter Rating
Main Drive 4 MW with 200% overload capability 9 MVA
Tension Reel 1 4 MW with 200% overload capability 9 MVA
Tension Reel 2 4 MW with 200% overload capability 9 MVA
Total Supply
with individual 3 x 4 MVA with 200% overload capability 3 x 9 MVA = 27 MVA
drives
Total Supply
with Common 1.2a x 4 MVA with 200% overload capability 2 x 7 MVA = 14 MVA
DC bus
a.Dimensioning factor
2.3.3 Mining Applications

The mining sector includes a wide field of drive applications. Depending
on the process needs the requirements vary.
The main reasons for choosing the ACS 6000 in mining applications are:
• High reliability
• High torque over entire speed range
• Full 4 quadrant operation with active rectifier
• Reduced energy consumption with common DC bus concept
• Small footprint.

Mine Hoists Figure 2-12 shows an example of a mine hoist with double inverter unit for
very low speed and high overload capability.
Mains
Synchronization voltage
Aux. power
Excitation power
TEU
ARU CBU INU INU WCU EXU COU
Aux.
Ctrl
Control
I/O
TEU TEU
SM
AC DC
DC AC PG
Figure 2-12 Mine Hoist

Overland Conveyor Long overland conveyors may have an overall length of several kilome-
ters. In terrains with long declining sections high braking capabilities are
needed and the drive is mainly operating in regenerative mode. Regener-
ative braking requirements can be met optimally by using the ACS 6000
with active rectifier.
Figure 2-13 shows an example with four parallel induction motors driving
an overland conveyor belt.
Mains
Aux. power
Aux. power
Synch. Reference
TEU TEU
COU ARU ARU CBU INU INU INU INU WCU COU COU COU COU
Aux. Aux. Aux. Aux.

Aux.
Control Control Control Control Control

I/O I/O I/O I/O I/O
TEU TEU TEU TEU
IM IM IM IM
4 x 2 MW
Figure 2-13 Overland Conveyor


Chapter 3 - Key Technologies
3.1 General
ABB has a vast experience in building high power converters and has
always been a leader in research, development and implementation of the
most advanced technologies.
The ACS 6000 represents ABBs most advanced converter. The key tech-
nologies described in this chapter distinguish the ACS 6000 from other
converters on the market.
3.2 Direct Torque Control
3.2.1 DTC Principle

Direct Torque Control is a unique motor control method for AC drives.
Switching of the inverter is directly controlled in accordance with the motor
core variables flux and torque.
Torque
reference
Torque Torque
reference and flux Switching =
Speed Speed controller
REF comparator logic
reference control
Actual
Speed
PID Switch
Positions
Motor model Voltage
Current
IM
3~
Figure 3-1 DTC Block Diagram for Asynchronous Motors

Torque
reference
Torque
Torque and flux Switching =
Speed Speed REF logic
reference comparator
reference control
controller
Actual
Speed & PID Switch
Position Positions
- Motor model
- Excitation Voltage
control Current
SM
3~
PG
SE
Figure 3-2 DTC Block Diagram for Synchronous Motors

The measured motor currents and DC link voltages are inputs to an adap-
tive motor model which produces exact values of torque and flux
every 25 µs. Motor torque and flux comparators compare the actual
values to reference values which are produced by the torque and flux
reference controllers.
Depending on the outputs from the hysteresis controllers, the optimum
switching logic directly determines the optimum inverter switch positions
every 50 µs. Switching takes place whenever required while in conven-
tional Pulse Width Modulation (PWM) controlled drives switching is done
only in predetermined patterns which results in slower response times.
3.2.2 DTC Performance

Figure 3-3 illustrates a typical dynamic speed response caused by a load
step.
PWM DC drive DTC

with encoder with encoder with encoder
Static speed error ± 0.01 % ± 0.01 % ± 0.01 %

Dynamic speed error 0.3 %sec 0.3 %sec 0.2 %sec
Speed 200 Torque 2000 Torque

(rpm) (kNm)
150
Value depending on
Speed
process
100
0
0 1000 2000 3000 4000 5000 Time (ms)
Figure 3-3 DTC: Typical Dynamic Speed Response

In many applications there is no need for speed and position encoders to

meet the performance requirements. For detailed information see Table 3-
1 and Appendix A - Technical Data.
The example in Figure 3-4 shows the response to a setpoint change.
Torque response times can be reduced substantially if DTC is used
instead of Pulse Width Modulation.
Typical torque step Torque:

response times at 70% speed: DTC
• DTC 3 ms
• PWM flux vector 10…20 ms
• PWM > 150 ms PWM
(scalar control)
Figure 3-4 DTC vs. PWM: Typical Torque Response Times
Table 3-1 Methods of Direct Torque Control
Direct Torque Control Direct Torque Control

Current Vector Control
(Asynchronous Motor) (Synchronous Motor)
Switching is based on core motor variables flux and Switching is based on the
torque separate control of
magnetic field and torque
producing components of
current
Shaft speed and position Mechanical speed is Mechanical speed is

are not required (high essential. Requires shaft essential. Requires shaft
performance applications speed and position speed and position
as for example in the (measured or estimated) (measured or estimated)
mining and metal industry
require speed encoders)
Each inverter switching process is determined Inverter switching is based

separately (every 50 µs) on average references to a
pulse width modulator
resulting in delays in
response and unnecessary
switching
Torque step rise time is less than 3 ms at 70% speed Torque step rise time
closed loop: 10 to 20 ms
sensorless: 100 to 200 ms
For more information on DTC, please refer to the Technical Guide No. 1
Direct Torque Control (3AFY 58056685 R0025).

3.3 IGCT Power Semiconductors
The Integrated Gate Commutated Thyristor is a power semiconductor

switching device specifically developed for medium voltage converters.
The IGCT is based on thyristor technology and is capable to switch on and
off much faster than a GTO.
Gate commutated
thyristor
Gate unit
Integrated Gate
Commutated
Thyristor
Figure 3-5 IGCT

The IGCT technology combines the advantages of GTOs and IGBTs as
shown in Table 3-2.

Table 3-2 IGCT Technology Compared to GTO and IGBT
GTO Thyristor High-Voltage IGBT IGCT Advantages
Switching • High blocking • High switching • High blocking

Technology voltage frequency voltage
• Low on-state • Low switching • High switching
losses losses frequency
• Snubberless • Low switching
losses
• Low conduction
losses
• Snubberless
Equipment • Proven reliability • Modular design • Proven reliability

Design • Compact • Allows compact
• Fuseless design and modular
equipment design
• Simple topologies
with low parts
count
• Fuseless design
3.4 Active Rectifier Unit
The active rectifier unit is a self commutated 6-pulse, three-level voltage

source inverter with IGCT technology. The ARU can be combined to 12-
pulse and 24-pulse systems.
3.4.1 Operating Principle

The ARU converts the transformer secondary AC voltage to DC in order
to charge the DC link capacitors. The DC link voltage is kept constant.
Depending on the motor operation mode (driving or braking), the ARU
draws or feeds energy from or to the line in order to manage the energy
flow (see Figure 3-6).
Energy Flow in Driving Mode
AC line Votage imposed DC link

voltage by ARU voltage
ARU INU
M
= =
Energy Flow in Braking Mode
Figure 3-6 Converter Principle Diagram

ARU and INU are identical. Both circuits have an AC and a DC connection.
The DC sides are connected to the DC link capacitor. Therefore the
system is symmetrical.
In driving operation the ARU behaves like an INU in braking mode. In
braking operation the ARU behaves like an INU in driving mode as shown
in Figure 3-8.
3.4.2 Control Principle

The ARU connects the three phases to DC (+), DC (NP) and DC (-)
according to a certain pattern as in the example shown in Figure 3-7. The
resulting ARU voltage patterns define the transformer secondary voltage.
The transformer primary side is connected to the supply network.
U ARU
Figure 3-7 Phase Voltage Created by ARU

The voltage difference between transformer primary and secondary sides
is applied to the leakage inductance and determines the transformer
current. By varying phase angle and magnitude of the transformer
secondary voltage by the ARU the current can be controlled (see Figure
3-8).

Ûtrans
ARU
Ûline Û1 ARU
q
Block Diagram
Ûtrans
Ûline
Ûtrans
Û1 ARU
Îline ϕARU
Îline
Ûline Û1 ARU
d
Equivalent Circuit Diagram Phasor Diagram
Figure 3-8 Vector Control Principle
3.4.3 Power Factor Control

By selecting an appropriate ARU pulse pattern the transformer current will
be in phase with the line voltage which means operation at unity power
factor (cos phi = 1). This is the standard operation mode.
Optionally the power factor can be controlled between 0.8 leading and 0.8
lagging.
3.4.4 Optimized Pulse Patterns

The ARU voltage pattern does not correspond to a sinewave. Therefore
the voltage contains harmonics. The used pulse patterns are optimized to
minimize the lowest harmonics.
The optimized patterns are stored in a lookup table and the controller
selects the correct pattern depending on the system conditions.

3.4.5 Control Block Diagram

The ARU control block diagram is shown in Figure 3-9. For further details
on the active rectifier unit circuitry please refer to Chapter 5 - Description
of Modules, Active Rectifier Unit (ARU), page 59.
DC link voltage control
Q ref
UDC ref
Vector
control Modulator
(optimized
pulse patterns) =
UA Synchronization
UB IA,B,C
(PLL)
UC Meas. UDC+ UDC-
Figure 3-9 Active Rectifier Control Block Diagram
3.5 Line Supply Unit
The line supply unit is a 12-pulse diode rectifier. Two three-phase AC

systems are supplied to the LSU from the converter transformer. 24-pulse
configurations are possible with double LSU.
The line supply unit provides the following features:
• Two quadrant operation
• Operation at constant power factor of about 0.95
• Converter protection with fuseless main circuitry.
For further details on the LSU refer to Chapter 5 - Description of Modules,
Line Supply Unit (LSU), page 57.

3.6 Common DC Bus
The common DC bus connects all rectifier and inverter modules on the DC
side.
3.6.1 Principle
The ACS 6000 is based on the voltage source inverter technology. The
rectifier and the inverter are connected to the same DC link capacitor. See
also Figure 3-6. Rectifier and inverter operations are decoupled. There-
fore it is possible to connect more than one motor inverter and rectifier to
the same common DC link. This way the ACS 6000 can supply more than
one motor or big motors (Figure 3-10).
AC line
voltage
ARU INU
M
= =
ARU INU
M
= =
INU
M
AC line =
voltage
INU
M
=
ARU INU
M
= =
Figure 3-10 Common DC Bus Principle
3.6.2 Advantages
Modularity The ACS 6000 modularity is based on the common DC bus principle. With
only two sizes of inverter modules (7 and 9 MVA) any motor or combina-
tion of motors in the range of 3 .. 27 MVA can be supplied.

Multi-motor Various combinations of synchronous and asynchronous motors are

Configurations possible. The number of system components as well as the footprint can
be reduced.
By integrating more than one drive into one converter the braking energy
generated in one motor can be transferred to other inverters via the
common DC bus without loading the rectifier.

Chapter 4 - Converter Configuration and Hardware
4.1 Overview
This chapter provides information on the modular concept, configuration

guidelines and the converter design including cabinet design, busbars and
grounding, the auxiliary supply system and the cooling system.
4.2 Modular Concept
The ACS 6000 is based on a modular product platform for megawatt class
medium voltage drives. Each module contains a functional unit (e.g. LSU,
ARU, INU, WCU) and consists of a cabinet section. The optimum config-
uration for a specific application can be reached by combining modules
with minimum engineering effort.
Figure 4-1 and Figure 4-3 provide two examples for typical cabinet
layouts. A detailed description for each module is provided in Chapter 5 -
Description of Modules.
4900
800 1000 1500 800 800
TEU
LSU INU CBU WCU
COU
2000
2200
1000
500
750
800
800
800
Figure 4-1 Cabinet Layout: Basic Configuration

LSU TEU/COU INU CBU WCU
Figure 4-2 ACS 6000 Basic Configuration (Marine Version)
12000
800 800 800 1000 1500 800 600 800 1500 1000 800 800 800
TEU TEU
EXU WCU LSU INU CBU ISU CBU INU LSU WCU EXU
COU COU
2000
2200
1000
500
500
600
750
750
800
800
800
800
800
800
800
800
Figure 4-3 Cabinet Layout: Redundant Converter (Planed Solution)

4.3 Configuration Guidelines
4.3.1 Required Application Data

ABB selects the appropriate converter configuration in accordance with
the following main data:
• Mains nominal frequency fn and short circuit power
• Number and type of connected motors, ratings of each motor (rated
power Pn, peak power Ppeak, braking capability, nominal, minimum
and maximum speed, number of poles)
• Type of application and other geographic and climatic requirements
(ambient temperature range, humidity, altitude of installation etc.).
4.3.2 Configuration Procedure

The converter is configured according to the following steps:
1 Select type of configuration (single-motor drive, multi-motor drive,
redundant or twin configuration)
2 Select field of application (marine or industrial)
3 In case of multi-motor drives indicate number of motors.
Select the appropriate inverter configuration for each motor based on
the main data mentioned in Required Application Data, page 49.
4 Select type of rectifier (ARU or LSU) based on process needs and
braking capability requirements.
5 If emergency braking capabilities are required an RBU or BCU has to
be added.
6 Select options if needed (e.g. customer interfaces). The available
options are listed in Chapter 8 - Options.
4.3.3 Configuration Rules

The following module sizes are available:
• ARU: 7 and 9 MVA
• INU: 7 and 9 MVA
• LSU: 7, 9 and 14 MVA
Several rectifier and inverter modules can be connected to the same
common DC bus in order to supply big motors or more than one motor.
The following restrictions have to be considered:
• Number of ARU + INU ≤ 6

• Total number of motors if supplied by ARU ≤ 4

• Total number of motors if supplied by LSU ≤ 5
• Number of ARU ≤ 3
• Number of LSU ≤ 4
• Combinations of ARU and LSU are not allowed
Note that these are only the most important rules. For a detailed list refer
to Appendix C - ACS 6000 Type Code.
The alignment of the modules is pre-defined.
4.4 Cabinet Design
4.4.1 Mechanical Design

Each module consists of one cabinet. The cabinets are bolted and
mounted on base frames.
The standard cabinets are rated IP 32. Ratings IP 44 and IP 54 are avail-
able as option.
The cabinets are equipped with doors. The main control equipment is
mounted on swing frames.
Transportation Small converters with a length of up to 7 meters will be shipped as one

unit. Bigger converters are separated into transportation units normally not
exceeding a length of 5 meters.
All transportation units are fitted with lifting lugs and must be lifted to their
position by crane.
Color The complete cabinet frame, including doors and walls, is galvanized. The
front and the side walls of the ACS 6000 cabinet are painted.
The standard color is RAL 7035 (light grey). Other colors are available as
option.
4.4.2 Electromagnetic Compatibility (EMC)

EMC is achieved by avoiding the use of paint on the inside of the cabinet
walls.
The joints between cabinet sections are bolted and EMC sealed. The
cabinet doors and the internal cable trays are also equipped with EMC
sealings.
The design of the ACS 6000 fulfills the requirements of international stan-
dards (see Appendix B - Applicable Codes and Standards).

4.4.3 Safety Aspects
Door Interlocking Medium voltage cabinets are equipped with an electromechanical inter-
locking system. The door locks are released if the safety grounding switch
is closed and the auxiliary voltage is on. The doors are equipped with posi-
tion switches. The safety grounding switch is released for opening only if
all the doors are closed.
The doors of COU, EXU, CIU and WCU are not part of the interlocking
system and may also be opened during drive operation.
Cabinet Temperature The cabinet temperature is monitored by a thermostat.
Protective Earth (PE) The PE busbar (protected earth) is installed through all cabinets (see
Busbars and Grounding, page 51).
Cabinet Labelling Danger areas are clearly marked with warning labels.
4.5 Busbars and Grounding
Internal AC and DC power connections between modules are made via

busbars.
The busbars are made of copper and the modules are interconnected
partly with flexible couplers.
Figure 4-4 shows the busbar arrangement in a typical cabinet layout:
Cable Entry from torp
LSU TEU INU CBU WCU EXU (CIU)
DC (-)
DC (NP)
DC (+)
1L1
1L2
1L3
L3
L2
L1
2L3
2L2
2L1
PG
PE
System ground Cable entry from bottom PG to PE connection in CBU

Figure 4-4 Arrangement of Busbars
AC Busbars AC power inputs and outputs which are located in the TEU are connected
to ARU, LSU and INU. The corresponding busbars are marked with 1L1,
1L2, 1L3, 2L1,2L2, 2L3 and L1, L2, L3.

DC Busbars The DC busbars connecting ARU, LSU and INU to the CBU are located in
the upper part of the converter. The corresponding busbars are marked
with DC (+), DC (-) and DC (NP). Up to three DC busbar arrangements can
be installed.
Safety Ground A safety ground busbar (protective earth, PE) is installed through all
converter cabinets (in the front bottom area of the cabinets as shown in
Figure 4-4). At one point (inside the terminal unit which is closest to the
capacitor bank unit) it must be connected to system ground. The connec-
tion to system ground has to be established in compliance with local regu-
lations.
Power Ground Cable shields must be connected to the converter in order to allow proper
operation. A separate conductor (power ground, PG) is installed since it is
not allowed to use the protective earth for operating currents. The shield
potential is grounded in the CBU by connecting PG to PE.
4.6 Auxiliary Supply System
The auxiliary voltages are provided by the factory network. The supply
cables are connected in the control part of the water cooling unit and inter-
nally distributed to the cabinet sections as shown in Figure 4-5.
For full ride-through capabilities a safe line needs to be supplied by the
customer.
To shut down the drive safely, if the auxiliary power is lost, a UPS is not
needed in all cases.
The following three auxiliary supply concepts are available depending on
the required ride-through capabilities.
4.6.1 AC Safe Line

The basic auxiliary concept uses an external uninterruptible power supply
with AC output ("AC safe line", see Figure 4-5).
The following voltage levels are required:
• 110 - 230 VAC,1 phase, via external uninterruptible power supply for
control and gate unit supply
• 380 - 690 VAC, 3 phase, for cooling pumps and capacitor bank unit
charging (no safe line).
Note that for synchronous motor drives a separate supply for excitation is
needed (see Chapter 5 - Description of Modules, Excitation Unit (EXU),
page 83).

380 - 690 VAC (3~)
(ext. UPS)
110 - 230 VAC
WCU COU LSU 1…2 ARU / INU 1…3 CBU
To other
modules
(if multi-drive)
230 VAC
27 VDC
(GUSP)
M M
Charging
Unit
24 VDC 24 VDC 27 VDC 24 VDC
Figure 4-5 "AC Safe Line" Auxiliary Concept
4.6.2 DC Safe Line

An alternative auxiliary concept uses an external uninterruptible power
supply with DC output ("DC safe line", see Figure 4-6).
• 110 or 220 VDC, via external uninterruptible power supply for control
and gate unit supply
• 380 - 690 VAC, 3 phase, for cooling pumps and capacitor bank unit
charging (no safe line).
page 83).

380 - 690 VAC (3~)
(ext. UPS)
110 / 220 VDC
WCU COU LSU 1…2 ARU / INU 1…3 CBU
To other
modules
(if multi-drive)
110 / 220 VDC
27 VDC
(GUSP)
M M
Charging
Unit
Figure 4-6 "DC Safe Line" Auxiliary Concept
4.6.3 No Safe Line

If no uninterruptible power supply is required, the internal auxiliary backup
capacitor for control enables a short-term energy supply of 0.5 s ... 3 s.
Also in this case a safe shutdown is guaranteed, however the drive has no
ride-through capabilities (see Figure 4-7).
• 380 - 690 VAC, 3 phase, for control and gate unit supply as well as
for cooling pumps and capacitor bank unit charging.
page 83).

WCU 380 - 690 VAC (3~) COU LSU 1…2 ARU / INU 1…3 CBU
To other
modules
(if multi-drive)
300 VDC
27 VDC
(GUSP)
M M
Charging
Unit
Figure 4-7 "No Safe Line" Auxiliary Concept
4.7 Cooling System
The ACS 6000 is equipped with a water cooling circuit for the main power
components. Natural air convection inside the cabinets is used for cooling
the control equipment and other components. Cooling pumps and heat
exchanger are installed inside the WCU. The WCU is accessible for main-
tenance, even if the system is running.
In case of redundant configurations two separate water cooling circuits
can be provided.
For further details on the cooling system refer to Chapter 5 - Description
of Modules.
LSU / CBU INU WCU EXU COU

ARU
Cooling pumps Heat exchanger
Figure 4-8 Principle Diagram of the Water Cooling Circuit


Chapter 5 - Description of Modules
5.1 Overview
This chapter provides a description of each individual module (cabinet

section). Detailed information on the cabinet layout, the module versions
as well as on the monitoring and protection devices is given.
5.2 Line Supply Unit (LSU)
5.2.1 Overview
The line supply unit rectifies the AC line voltage and supplies the energy
to the DC link capacitors. The line supply unit is a 12-pulse diode rectifier
and contains also a thyristor crowbar for protection.
Cable duct and

control section
di/dt limiting reactors
Rectifier monitoring
Snubber capacitor
Diode stacks
(including crowbar)
Pulse transformer
Snubber resistors
Water inlet tube
Safety ground
Figure 5-1 LSU Cabinet Layout

5.2.2 Main Components

The line supply unit consists of the following main components:
• 12-pulse diode rectifier
• Snubber circuit
The snubber circuit limits dv/dt across the diodes and crowbar thyris-
tors.
• di/dt choke
di/dt chokes define the current rise in the crowbar.
• Crowbar
The rectifier can be shorted by the crowbar for protection purposes
(protection firing).
• Pulse interface and pulse transmitters
The thyristor firing pulses coming from the pulse interface are sent to
the thyristors via pulse transmitters.
• Rectifier monitoring
Unbalances in the rectifier are detected by the rectifier monitoring.
5.2.3 Circuit Diagram
Thyristor
Crowbar
di/dt Choke
DC (+)
L1
L2
L3
Rnp
DC (NP)
L1
L2
L3
di/dt Choke
DC (-)
Diode Rectifier Snubber Circuit
Diode
Rectifier
Monitoring
To / from
Pulse Interface Board INU
Figure 5-2 LSU Circuit Diagram

5.2.4 Types and Sizes

Three different types of line supply units are available:
• 7 MVA module
• 9 MVA module
• 14 MVA module.
They differ in their electrical ratings. The mechanical dimensions of all
LSU cabinets are the same.
If two line supply units are used in parallel, 24-pulse rectification can be
obtained. Up to four line supply units can be used in parallel (see also
Chapter 4 - Converter Configuration and Hardware, Configuration Guide-
lines, page 49).
5.3 Active Rectifier Unit (ARU)
5.3.1 Overview
The active rectifier unit controls the energy flow to the DC link. The DC link
voltage is kept constant irrespective of supply network changes. The ARU
allows four-quadrant operation. It is a self-commutated, 6-pulse 3-level
voltage source inverter.
Gate unit supply

Voltage measurement
Phase modules
Current measurement
Water tubes
Anti saturation equipment Safety ground
Figure 5-3 ARU Cabinet Layout


The active rectifier unit consists of the following main components:
• Phase modules
A phase module consists of integrated gate commutated thyristors,
diodes and clamp capacitors.
Cooling water outlet
Power Terminals
IGCTs Cooling water inlet

Antiparallel diodes
Figure 5-4 Phase Module with IGCTs

• Gate unit power supply (GUSP)
The potentially separated gate unit power supply provides energy to
the IGCT.
• Clamping circuit
di/dt chokes protect the circuit from excessive rises in current. The
clamping diodes are used as freewheeling diodes for the di/dt
chokes.
• EMC filter
The EMC filter protects the transformer from excessive voltage
slopes (dv/dt is limited to 1.7 kV/µs).

• Interface board (INT)

The interface board acts as a front-end for the communication with
the control system in the COU. Data between the interface board and
the control system is exchanged via fiber optic links.
The interface board includes the pulse firing logic and fast protection
functions.
Gate firing signals are transmitted to the IGCTs via fiber optic cables.
• Fast short circuit detection (FSCD)
These boards detect short circuits in the main power circuit.
• Anti-saturation equipment (ASE)
The anti-saturation equipment prevents from transformer saturation.
• Voltage and current measurement devices
The DC voltage is scaled on the high voltage divider board (HVD).
The resulting signal and the signals from the AC current transducers
are converted to digital signals on the current and voltage measuring
interface board (CVMI) and transmitted via fiber optic cables to the
INT board.
FSCD
board
di/dt choke
DC (+)
Rclamp
C
NPC
L1 DC (NP)
EMC C Rclamp
Filters
DC (-)
di/dt choke
FSCD HVD
board board
Gate firing pulses
ASE CMVI
GUSP board
= board
INT board COU
Other INT
Figure 5-5 ARU Local Control and Monitoring Equipment

DC (+)
L1
L2
L3
DC (NP)
DC (-)
EMC Filter Phase modules Clamping circuit
Figure 5-6 ARU Circuit Diagram

Two different types of active rectifier units are available:
• The 7 MVA module
• The 9 MVA module.
They differ in their electrical ratings. The mechanical dimensions are the
same.
For larger power ratings of up to 27 MVA, up to three ARUs can be
connected in parallel. The result on DC side are 12-pulse and 18-pulse
ARUs (see also Chapter 4 - Converter Configuration and Hardware,
Configuration Guidelines, page 49).
5.4 Inverter Unit (INU)
5.4.1 Overview
The inverter unit inverts the DC voltage to the AC motor voltage. The INU
allows four-quadrant operation. It is a self-commutated, 6-pulse 3-level
voltage source inverter.
The layout and equipment of the INU is identical with the ARU except for
the anti-saturation equipment which is used only in the ARU. For details
refer to Active Rectifier Unit (ARU), page 59.

DC (+)
L1
L2
L3
DC (NP)
DC (-)
Clamping circuit Phase modules EMC Filter
Figure 5-7 INU Circuit Diagram

Two different types of inverter units are available:
• The 7 MVA module
• The 9 MVA module.
They differ in their electrical ratings. The mechanical dimensions are the
same.
For larger power ratings and for multi-motor configurations, up to five INUs
can be connected to the same DC link (see also Chapter 4 - Converter
Configuration and Hardware, Configuration Guidelines, page 49).
5.5 Capacitor Bank Unit (CBU)
5.5.1 Overview
The capacitor bank unit smoothes the intermediate DC voltage and decou-
ples the rectifier from the inverter.
The capacitor bank unit contains DC link capacitors, a charging unit and
an earth isolator.

Cable duct
DC busbars
DC link capacitors
Water inlet tube
Safety ground
Figure 5-8 CBU Cabinet Layout

The capacitor bank unit consists of the following main components:
• Capacitors
The capacitors are water-cooled.
• Charging unit
The charging unit charges the capacitors before the converter is
connected to the mains. This avoids excessive inrush currents when
the main circuit breaker is closed.
The charging unit consists of an auxiliary transformer and a small
diode rectifier.
• Discharging unit (optional)
The discharging unit is needed to discharge the DC link capacitors if
the converter is shutdown and no VLU, RBU or BCU is installed.

• Earth isolator (safety grounding switch)

An earth isolator is provided to ground the converter. It is a safety
device which can only be closed, if the DC link capacitors are
discharged.
• Coupling device for insulation resistance monitoring (optional).
Charging unit
Capacitors
DC (+)
DC (NP)
DC (-)
Earth isolator
PE
Figure 5-9 CBU Circuit Diagram

The capacitor bank unit is available in two different sizes depending on the
converter ratings. For high power converters, up to two capacitor bank
units can be installed on the same DC link.

5.6 Terminal Unit (TEU)
5.6.1 Overview
Mains and motor power cables are connected in the TEU. They can be
installed either from the top or from the bottom of the cabinet.
Cable duct
AC busbars
Ground terminals
Power cable entry

section (bottom)
Power ground
Protective earth
Figure 5-10 TEU Cabinet Layout
5.6.2 Types
Two types are used:
• TEU with single input or output terminal field
• TEU with double terminal field

5.7 Control Unit (COU)
5.7.1 Overview
The control unit is responsible for the converter control, monitoring and
protection functions. It includes the interface for the process control
system and the local control panel.
The control unit is mounted on a swing frame inside the TEU behind the
front door.
Cable duct and
terminals
S800 I/O modules
Power supply
Undervoltage moni-
toring
CDP 312 control

panel
Compact starter
(charging)
Pushbuttons
Safety relays (E-off,

E-stop)
AMC3 board
Aux. relays
Optical electrical
interface board
Socket
Mini circuit breakers
MCB control relays
Fuse disconnector
switches
Aux. transformers
Aux. power back-up
(approx. 0.5 s)
Figure 5-11 COU Swing Frame Layout


The control unit consists of the following main components:
• AMC3 Controller
The AMC3 controller board is a digital signal processing system used
for motor inverter and rectifier control. For more information see
Chapter 6 - Control System and Process Interfaces, AMC3 Controller,
page 88.
• S800 I/O modules
The converter related hardwired I/Os are connected to the AMC3
controller via standard S800 modules.
• CDP 312 control panel
The CDP 312 control panel is the basic user interface for local oper-
ation. For further details see Chapter 6 - Control System and Process
Interfaces, CDP 312 Control Panel, page 93.
• Interface to process control system
Various fieldbus interfaces are available. For further details see
Chapter 6 - Control System and Process Interfaces, Fieldbus Inter-
faces, page 103.
• Encoders
Optional speed and position encoders can be connected to the COU.
• Auxiliary power supply
Auxiliary power system components located in the COU are
described in Chapter 4 - Converter Configuration and Hardware,
Auxiliary Supply System, page 52.
5.7.3 Types
Each TEU can contain one COU swing frame. Depending on the type of
TEU, two different types of COU swing frames are used.
One COU swing frame is needed for each motor. In case an ARU is part
of the drive line-up the ARU controller is integrated into the swing frame of
the first COU of the drive (the first COU is always the COU next to the line
rectifier).
For details on the control structure, refer to Chapter 6 - Control System
and Process Interfaces, Control Hardware Concept, page 87.

5.8 Water Cooling Unit (WCU)
5.8.1 Overview
The water cooling unit feeds the cooling water to the main power compo-
nents (Figure 5-12), transfers the heat to an external water circuit and
continuously purifies the cooling water. Additionally, natural air convection
inside the cabinets is used for cooling.
LSU / CBU INU WCU EXU COU

ARU
Figure 5-12 Cooling Circuit: Principle Diagram
Aux. distribution / process I/O
Filter
Main water return pipe

Pump motors
Water pumps
Ion exchanger
Heat exchanger
Main water supply pipe
Figure 5-13 WCU (small) Cabinet Layout

Main water return

pipe
Filter
Pump motors
Raw water outlet

flange (behind
swing frame)
Water pumps
Heat exchanger
Ion exchanger
CIW
Raw water inlet
flange
Main water supply
pipe
Figure 5-14 WCU (large) Cabinet Layout with CIW

The water cooling unit consists of the following main components:
• Water pumps
The WCU contains two water pumps. One pump is running while the
other is in hot standby. The pump in standby mode can be serviced
while the converter is running. The pumps switch from standby to
running mode and vice versa in regular intervals.
• Heat exchanger
Water to water heat exchanger between the deionized internal water
cooling circuit and the raw water circuit.
• Expansion vessel / tank
The expansion vessel or tank is used for pressure compensation.
• Water conditioning circuit
• Control and monitoring instrumentation
Temperature, pressure and conductivity are monitored in the deion-
ized water circuit.

• Auxiliary voltage supply

The auxiliary voltages provided by the factory network are connected
in the control section of the WCU and internally distributed to the
other cabinets.
• Optional hardwired process I/O
For details see Chapter 6 - Control System and Process Interfaces,
Hardwired Process I/Os, page 106.
5.8.3 Water Cooling Circuit

The water cooling system consists of three circuits.
1 Deionized water circuit:
It contains deionized water that transfers heat losses (from the equip-
ment) to the water to water heat exchanger in the water cooling unit.
There are two different types of cooling circuits:
• The closed circuit (see Figure 5-15) is equipped with
a pressurized expansion vessel.
It is used in marine applications and when glycol is
added to the internal cooling circuit.
• The open circuit (see Figure 5-16) is equipped with
an (open) expansion tank.
2 Industrial water circuit:
It contains industrial water which transfers heat losses from the water
to water heat exchanger to the exterior.
3 Water treatment circuit:
The water treatment circuit continuously purifies the cooling water of
the deionized water circuit in order to keep the conductivity low. The
circuit includes a make-up water connection and a flow measure-
ment.
General technical data are listed in Appendix A - Technical Data.

2 7
6
3
5
1
Figure 5-15 Water Cooling Circuit, Example for Closed Circuit
No./ No./ No./

Explanation Explanation Explanation
Abbr. Abbr. Abbr.
1 Deionized water to converter C1 Expansion vessel LS Level sensor
2 Deionized water from C2 Deionizer filter PI Pressure indicator

converter
3 Deionized water to excitation C3 Deaeration vessel PT Pressure transmitter

unit
4 Deionized water from E1 Heat exchanger QTI Conductivity transmitter

excitation unit and indicator
5 Make-up water inlet F1 Pressure relief valve TT Temperature transmitter
6 Industrial water inlet (flange) FI Flow indicator V Valve
7 Industrial water outlet (flange) FS Flow sensor Z1 Filter

2 9
3
7
1 8
Figure 5-16 Water Cooling Circuit, Example for Open Circuit
No./ No./ No./

Explanation Explanation Explanation
Abbr. Abbr. Abbr.
1 Deionized water to converter 9 Industrial water outlet PI Pressure indicator

(flange)
2 Deionized water from C1 Expansion vessel PT Pressure transmitter

converter
3 Deionized water to excitation C2 Deionizer filter TT Temperature transmitter

unit
4 Deionized water from E1 Heat exchanger V Valve

excitation unit
5 Coupling 1" male FI Flow indicator W Hose
6 Coupling 1" female FS Flow sensor Z2 Filter
7 Make-up water inlet LI Level indicator
8 Industrial water inlet (flange) LS Level sensor
5.8.4 Cooling Control

Cooling control and monitoring is included in the main converter control
system which is located in the control unit. The Control Water Unit (CWU)
is the frontend for the signal exchange with the COU.

The water pump is switched on, as soon as the auxiliary power supply is
available and no emergency off signal is present. When the pump has
started, the water pressure monitoring system is enabled after a short
delay.
The three-way valve in the industrial water circuit is controlled in relation
to the temperature of the deionized water.
If the cooling system is shut off, the water conductivity increases after
some time. Therefore, a conductivity check routine is automatically carried
out if the pumps are stopped for more than 10 minutes.
Auxiliary Power The auxiliary power is distributed from the water cooling unit. Refer to
Distribution Chapter 4 - Converter Configuration and Hardware, Auxiliary Supply
System, page 52 for an overview of the auxiliary distribution circuit.

The water cooling unit is available in five different sizes depending on the
converter ratings: two sizes for closed circuit and three sizes for open
circuit.
Optional I/Os for transformer and motor monitoring for single-motor drives
are located in the water cooling unit. For additional information refer to
Chapter 6 - Control System and Process Interfaces, I/O Configurations for
Single-motor Drives, page 100.
5.9 Customer Interface Unit (CIU)
5.9.1 Overview
Optional I/Os for transformer and motor monitoring for multi-motor drives
are located in the customer interface unit. I/O modules with predefined
I/Os are called CIU1, I/O modules with programmable AC80 are called
CIU2.
Engineered interfaces are always located in a separate cabinet and called
CIUe.

Figure 5-17 CIUe, Typical Cabinet Layout

The customer interface unit consists of the following main components:
CIU1 • Five additional I/O modules (S800 modules) with predefined I/Os for
auxiliaries of each motor
• Predefined I/Os for transformer auxiliaries
CIU2 • Five additional I/O modules (S800 modules) and programmable

AC80 for auxiliaries of each motor
• I/Os for transformer auxiliaries
• CDP 80 control panel(s)
CIUe • Customer specific I/O configuration
5.9.3 Overview Drawing

For overview drawings on I/O configurations refer to Chapter 6 - Control
System and Process Interfaces, Figure 6-13 and Figure 6-14.


Three different types of customer interface units are available. Dependent
on whether predefined, programmable or engineered I/Os are required
they are called CIU1, CIU2 or CIUe.
Optional I/Os for transformer and motor monitoring for single-motor drives
are located in the control section of the water cooling unit (CIW). For addi-
tional information refer to Chapter 6 - Control System and Process Inter-
faces, I/O Configurations for Single-motor Drives, page 100.
5.10 Input Filter Unit (IFU)
5.10.1 Overview
The input filter unit reduces harmonic voltages injected to the supply
network. It is used in combination with 6-pulse ARUs connected to a weak
supply network. The IFU is a tuned filter located between the converter
transformer and the ARU.
Filter resistors
Filter capacitors
Figure 5-18 IFU Cabinet Layout


The input filter unit consists of the following main components:
• Decoupling reactors in the main circuit
• Filter reactors
• Filter capacitors
• Damping resistors
TEU IFU ARU

L 1 TEU L 1 ARU
L 2 TEU L 2 ARU
L 3 TEU L 3 ARU
Figure 5-19 IFU Circuit Diagram

The size of the input filter unit depends on the ARU ratings. If an IFU is
used, the continuous power of the ARU is derated to max. 7 MVA.
5.11 Voltage Limiter Unit (VLU)
5.11.1 Overview
The voltage limiter unit can dynamically discharge the DC link capacitors
to the normal level in case of overvoltage. The VLU consists of a set of
casted resistors which can be switched on and off by IGCTs.
The VLU is used in dynamic applications (typically metals and mining) with
high requirements for torque accuracy.

Air-cooled resistors
IGCTs
Figure 5-20 VLU Cabinet Layout

The voltage limiter unit consists of the following main components:
• Resistors
The resistors are protected against overload by a software based
thermal model.
• VLU stack with IGCTs, diodes and snubber circuit
• VLU short circuit detection (VLSCD)
Correct switching of the IGCTs is monitored based on feedback
signals from the VLSCD.


.
VLU DC (+)
VLSCD
board
DC (NP)
VLSCD
board
DC (-)
INU
INT-
Board
Figure 5-21 VLU Circuit Diagram

The ratings of the voltage limiter unit depend on the drive size.
5.12 Resistor Braking Unit (RBU)
5.12.1 Overview
The resistor braking unit is used to dissipate braking energy where regen-
erative braking is not possible or emergency braking is required. The RBU
consists of a set of resistors (water-cooled) which can be switched on and
off by IGCTs. The RBU is connected to the common DC bus.
The RBU is typically used in combination with LSU.

RBU stack with IGCTs,

diodes and snubbers
Resistor (water-cooled)
Figure 5-22 RBU Cabinet Layout

The resistor braking unit consists of the following main components:
• Resistors
The resistors are protected against overload by a software based
thermal model.
• RBU stack with IGCTs, diodes and snubbers
• RBU short circuit detection (VLSCD)


.
RBU DC (+)
VLSCD
board
DC (NP)
VLSCD
board
DC (-)
INU
INT-
Board
Figure 5-23 RBU Circuit Diagram

The RBU is available in one size with a braking capability of 0.5 MW. The
total energy which can be dissipated in one braking cycle is 10 MWs. A
cool-down phase of 20 minutes is required between two cycles if the full
braking capability is used.
A second cabinet section containing only resistors can be installed if the
braking power of one RBU is not sufficient.
5.13 Braking Chopper Unit (BCU)
5.13.1 Overview
The braking chopper unit is used to dissipate braking energy where regen-
erative braking is not possible or emergency braking is required. The BCU
consists of a braking chopper and a connection part for external braking
resistors. The BCU is connected to the common DC bus.
The BCU is typically used in combination with LSU.


The braking chopper unit consists of the following main components:
• Braking chopper with IGCTs, diodes and snubber circuit
• Terminals for external braking resistors
• BCU short circuit detection (VLSCD)

.
DC (+)
BCU
VLSCD
board
External 1
braking DC (NP)
resistors 2
VLSCD
board
DC (-)
INU
INT-
Board
Figure 5-24 BCU Circuit Diagram

The BCU is available for various sizes and types of external braking resis-
tors. The electrical rating of the external resistors is based on the required
braking power and energy. The resistors connected to the positive DC
voltage (1 in Figure 5-24) must have the same electrical rating as the
resistors connected to the negative DC voltage (2 in Figure 5-24).

5.14 Isolator Unit (ISU)
5.14.1 Overview
The isolator unit is used to separate the DC link in two sections. The ISU
is only used in redundant configurations. The isolators can only be opened
if the drive is shutdown.
An example of an ACS 6000 configuration with ISU is shown in Chapter 2
- Types and Applications, Propulsion and Thruster for Shuttle and Service
Vessels, page 27.
5.15 Excitation Unit (EXU)
5.15.1 Overview
For the excitation of synchronous motors the EXU is available for two
types of excitation systems:
• Direct excitation
• Brushless excitation.
Overvoltage
protection resistor
Overvoltage protection
circuit
Current transducer
Thyristor bridge
Pulse transformers
Fuses
Shunt resistor for current

measurement
Input contactor
Figure 5-25 EXU Cabinet Layout (Direct Excitation)

5.15.2 Excitation Circuit
Direct Excitation A controlled 6-pulse thyristor rectifier fed by an excitation transformer

supplies the sliprings of the synchronous motor with DC current (Figure 5-
26).
6-pulse EXU
thyristor
rectifier
Excitation
transformer rotating part
Slip- SM
rings
Figure 5-26 Motor with Direct Excitation
Brushless Excitation A three-phase AC power controller in the EXU feeds a three-phase exci-
tation motor. The excitation motro with its rotating rectifier in the armature
generates the DC current required to produce the magnetic field in the
brushless synchronous motor (Figure 5-27).
For reversing motors the phases are changed automatically in the EXU .
3-phase EXU
AC power
controller
Excitation
transformer
rotating part
Excitation SM
motor
Rotating rectifier
Figure 5-27 Motor with Brushless Excitation

The excitation unit consists of the following main components:
• Converter with fuses
Direct excitation: The excitation converter is a standard 6-pulse
thyristor bridge (Figure 5-28). One leg consists of the thyristor valve
in series with a fuse and each thyristor is equipped with a RC snubber
circuit.

Brushless excitation: The configuration of the 3-phase AC power

controller is illustrated in Figure 5-29. Each phase consists of a pair
of antiparallel thyristors in series with a fuse. Each thyristor pair is
equipped with a RC snubber circuit.
The AC power controller is equipped with two additional pairs of anti-
parallel thyristors for phase interchange (when the sense of rotation
of the synchronous motor is reversed the phases are changed auto-
matically).
• Swing frame
All control boards are placed on the swing frame.
The AC power controller is operated in current control mode. The
Converter Control Board (CCB) controls the excitation current based
on the current reference coming from the AMC3 control board.
• Input terminals and input contactor
The input contactor is used for disconnecting the excitation circuit
from the supply network. It must not be actuated under load. There-
fore an input circuit breaker on the excitation transformer primary side
is needed.
• Instrumentation
Voltage and current measurement according to Figure 5-28 and
Figure 5-29.
An insulation resistance monitoring device is used in the direct exci-
tation converter to detect earth faults in the excitation circuit including
transformer secondary side and motor. Such a device is available as
option for the brushless excitation.
All thyristor fuses are monitored.
• Protection Devices
The EXU is protected against overvoltage by means of varistors on
the AC input side.
In addition, the output of the direct excitation converter is equipped
with a thyristor crowbar to protect the motor field windings from over-
voltage.

EXU Thyristor rectifier Overvoltage

protection device
U I
BOD
COU
Pulse amplifier
interface (PAI) CCB AMC3
Figure 5-28 EXU Circuit Diagram (Direct Excitation)
EXU
AC power controller
U I
U
COU
Pulse amplifier
interface (PAI) CCB AMC3
Figure 5-29 EXU Circuit Diagram (Brushless Excitation)

The EXU input voltage is in the range of 380-690 VAC, 3-phase.
Each synchronous motor which is connected to the ACS 6000 requires a
separate excitation unit.

Chapter 6 - Control System and Process Interfaces
6.1 Control Hardware Concept
The control system of the ACS 6000 is based on ABB‘s advanced Appli-
cation and Motor Controller (AMC3) which is used throughout the whole
ACS product family. Control, measurement and protections are fully
digital.
6.1.1 Overall Control Structure

The control system is characterized by a distributed structure (see Figure
6-1 and Figure 6-2). It is designed to support the modular concept of the
power equipment and to enable fast and reliable signal exchange.
COU Rectifier control Inverter control

PC Tool PC Tool
Process control
system Process control
system
CDP 312 CDP 312
FCI / FCI /
AC80 AC80 Mot
Fieldbus Process I/O Fieldbus S800
or
Process I/O
adapter FBA FBA
adapter
Rotor speed
RS 485
NTAC
AMC3 AMC3 GRB
Rotor position
VA...VC
SYN
PPCS
PPCS
PPCS
PPCS
INT / PFF
ARU INU EXU

PPCS
FT-link
CCB MUB
INT INT
PAI MUI
PPCS
PPCS
PPCS
PPCS
IOC
IOC
GDR
VNP to ground
HVD + CVMI HVD + CVMI

V to ground
Excitation
VDC-
FSCD
FSCD
FSCD
FSCD
VDC-
ASEB
ASEA
supply
IA...IC IA...IC IDC

vDC
VDC+ NP
VDC+
SM
PE
SE
Figure 6-1 Control Structure: ACS 6000 Single-motor Drive with ARU
and Synchronous Motor

COU Inverter control
PC Tool
Process control
system
FCI / CDP 312
AC80
Fieldbus
adapter Mot Process I/O
S800
or
Rotor speed (optional)

AMC3
NTAC
LSU INU
FT-link
INT
PPCS
PPCS
IOC
PINT
HVD + CVMI
VNP to ground
Diode
monitoring
VDC-
FSCD
FSCD
EAF
IA...IC
VDC+
IM
To NTAC (optional)
PG
(optional)
Figure 6-2 Control Structure: ACS 6000 with LSU and Asynchronous
Motor
6.1.2 AMC3 Controller

The AMC3 control board is the heart of the control system. It is based on
a signal processor which is widely used in ABB applications and motor
controllers. The main processor is a 100 MHz Motorola DSP.
The AMC3 board is located inside the TEU in a swing frame. It is equipped
with 2 PPCS and 8 DDCS fiber optic channels for communication with:
• Process controllers (via advant or fieldbus adapters)
• I/O devices

• Converter and excitation control interfaces

• Interface for service tools.
The PPCS and DDCS protocols are serial communication protocols and
are specially designed for fiber optic data transfer.
An RS-485 link is used to interface the CDP 312 control panel (for details
refer to CDP 312 Control Panel, page 93).
Active rectifier unit and inverter unit require separate AMC3 boards.
6.1.3 Control Hardware Topologies
Inverter Unit Control One AMC3 board in the control unit is used for inverter control. Fiber optic
links lead to inverter module(s).
Excitation Unit Control The current reference is provided by the AMC3 board of the inverter
control. The excitation current controller is implemented in the CCB board.
Fiber optic links lead to the excitation module. (An EXU is only needed
with synchronous motors.)
Line Supply Unit All rectifier and line related functions including main circuit breaker control
Control are implemented in the inverter control.
Active Rectifier Unit If the ACS 6000 is equipped with an active rectifier unit, control for the
Control active rectifier unit is independent of the inverter unit control. Active recti-
fier unit and inverter unit control hardware are basically the same.
In the basic configuration with 1 active rectifier unit and 1 inverter unit, two
independent AMC3 control boards are used (see Figure 6-3 a): one
processor is dedicated to the rectifier control and to the corresponding
communication links. A second processor controls the inverter unit.
Multi-motor drives require additional control units (see Figure 6-3 b, c).
Single-motor drives with multiple inverter units require only one AMC3
board for motor control (see Figure 6-3 d).
PPCS Branching Unit Parallel INUs supplying the same motor are controlled by one AMC3
board. The control signal is distributed to the individual INUs via a PPCS
branching unit (Figure 6-3 c).
A second AMC3 board and a PPCS branching unit is required for all
parallel ARUs.
Figure 6-3 provides an overview of ARU / INU control topologies.

A COU
AMC3 AMC3
PFF
ARU INU
INT INT
B COU COU
AMC3 AMC3 AMC3
PFF
ARU INU INU

INT INT INT
C
COU
AMC3 AMC3 AMC3
PUB / PFF
ARU ARU INU INU

INT INT INT INT
D COU
AMC3 AMC3
PUB / PFF PUB
ARU ARU INU INU

INT INT INT INT
Figure 6-3 Examples for Control Hardware Topologies

A: Single-motor Drive: 1 ARU and 1 INU: 1 COU
1 Board for Power Feed Forward (PFF)

B: Multi-motor Drive: 1 ARU and 2 INUs: 2 COUs

1 Board for Power Feed Forward (PFF)
C: Multi-motor Drive: 2 ARUs and 2 INUs: 2 COUs
1 Board for PPCS Branching and Power Feed Forward
(PFF)
D: Single-motor Drive: 2 ARUs and 2 INUs: 1 COU
2 Boards for PPCS Branching and Power Feed Forward
(PFF)
6.2 Software Concept
6.2.1 Control Software Structure
INU Control AMC3
AMCOS (AMC Operating System)
Function Block Motor Control

library (Fixed Application)
Fieldbus Adapter
Speed
Advant AC Application Controller
Controller
Program
S800 Process I/O
Modulator
Direct Torque Interface
CDP 312 Control Controller
Panel Panel Application
Magnetization
Reference to EXU
AMC Table
AMC3 ARU Control

AMCOS (AMC Operating System)
Function Block Rectifier Control

Library (Fixed Application)
Fieldbus Adapter
Advant AC Application
Controller Program
S800 Process I/O
DC voltage
CDP 312 Control and cosϕ Modulator
Controller Interface
Panel Panel Application
AMC Table
Figure 6-4 Software Block Diagram of the AMC3 Board

The control software of the ACS 6000 is of modular design. Similar to

other products of the ACS family, the software is written in the following
programming languages: Assembler, C, VHDL and Function Block
Programming Language. The major part of the software runs on the AMC3
board. Safe performance under all possible operating conditions has been
emphasized.
The control software is organized as follows (see Figure 6-4):
• Operating system (AMCOS)
• Motor control (INU) and rectifier control (ARU)
• Other fixed applications: speed control, main state machine, fault
handling, fast communication, master follower etc.
• Application control (with function block library), containing functions
that are specific to an individual type of installation or a project.
6.2.2 Operating System

The AMC operating system (AMCOS) is a real time multitasking operating
system with a very low cycle time, opening the way for new control appli-
cations (for details see Chapter 3 - Key Technologies, Direct Torque
Control, page 37). In addition to the basic operating system functions (task
scheduling, FLASH memory management etc.), it also offers standardized
interfaces and services such as the AMC table, I/O communication, diag-
nostics and more.
AMC Table The AMC table contains data for motor, rectifier and application control,
including the process I/O image. The AMC table is the data interface to
which all software blocks (fixed, application and panel application) have
access.
6.2.3 Motor and Rectifier Control Software

The fixed control software includes control algorithms which provide
optimum performance in conjunction with IGCTs: DTC in the inverter unit
and vector control with optimized pulse patterns in the active rectifier unit
are used to generate the switching sequences. See Chapter 3 - Key Tech-
nologies, Direct Torque Control, page 37 and Chapter 3 - Key Technolo-
gies, Optimized Pulse Patterns, page 43.
6.2.4 General Fault Handler

The general fault handler allows to classify each detected event according
to predefined functional groups and fault classes.
These groups are:
• Event
• Alarm
• Low Priority Trip (long delay)

• High Priority Trip (short delay)

• Immediate Trip
Various fault classes (which are defined separately for rectifier and
inverter) determine whether the main circuit breaker will be opened in case
of a trip.
6.2.5 Main State Machine

In both, ARU and INU, the start, stop and fault sequences are coordinated
in the main state machine. The main state machine is a predefined
program routine which decides on the optimum reaction to any event or
fault signal.
6.2.6 Application Program

The application software on the AMC3 board is programmed with the
Function Chart Builder (a graphical PC software tool). The Function Chart
Builder (FCB) makes use of a function block library consisting of a selec-
tion of preprogrammed software blocks.
The application software contains:
• I/O handling routines
• Customer and drive interfaces
• Selection logic for reference and control place
• Fault and alarm monitoring
• Drive operation sequences and interlocking
• Auxiliary device control
Panel Application The panel application takes care of the information exchange between the
AMC table and the CDP 312 control panel in local operation mode.
The PC interface to DriveWindow can be used to set parameters, access
measurement and diagnostic data and to control the converter in local
operation mode (as alternative to the CDP 312 control panel).
6.3 User Interfaces
6.3.1 CDP 312 Control Panel

The CDP 312 control panel is the basic user interface for local operation
of the ACS 6000. A separate control panel is provided for each AMC3
controller (i.e for each active rectifier unit /inverter unit). The detachable
panels are mounted on the front doors of the corresponding control units.

1 L 1242rpm I Alphanumeric Display

Control CURRENT 1415.00 A
SPEED 1242.0rpm (4 lines x 20 characters)
Panel
TORQUE 86.00 %
Display
ACT PAR FUNC DRIVE Control panel mode selection keys
Double up arrow, up arrow,

ENTER Double down arrow, down arrow
and enter keys
Control LOC RESET REF Local/remote, reset, reference and

Panel REM
start keys
Keypad
Forward, reverse and stop keys
Figure 6-5 CDP 312 Control Panel

The panel provides the following features:
• Enter startup data into the drive
• Control the drive by setting reference values and by giving Start, Stop
and Direction commands
• Display actual values (three values can be read simultaneously)
• Display and set parameters
• Display information on the last 64 fault events

6.3.2 Pushbuttons and Pilot Lamps
TEU COU
CDP 312 Control Panel

Functions:
Start and stop the motor
Set the reference value
INU status message display
Alarm and fault message display
Reset alarm and fault messages
Illuminated Pushbuttons
Switch auxiliaries on/off
Emergency Reset button

Resets emergency off
AUXILIARIES
OFF ON
Fault / Alarm lamp
Indicates alarm and fault conditions
EMERGENCY ALARM Emergency Off Button

RESET FAULT
Shuts down the drive, if activated during

operation
EMERGENCY OFF Prevents start-up of the drive, if activated at
standstill
Figure 6-6 INU Control Panel
6.3.3 PC-Tools
DriveWindow offers several functions for commissioning and monitoring
ABB products. All functions are available from the menuebar or the toolbar
of the program. In DriveWindow, the user has the choice between two
special displays and six different tools. For further details, see Chapter 8 -
Options, Service and Diagnostics, page 127.

6.4 Start and Stop Sequences
6.4.1 Local and Remote Control
Operation of the ACS 6000 is possible either by local or remote control.

The local control mode is set directly by pushing the LOC/REM push-
button on the CDP 312 control panel. Selecting the local control mode is
only possible if no remote request is coming from the overriding control.
On the panel display, local operation is indicated by an L (see figure
below). Remote control is indicated by an empty field.
1 L -> 0.0 rpm 0

LOC StateINU Rdy On
REM Motor SP 0.00 rpm
Power 0.0 %
1 -> 0.0 rpm 0

LOC StateINU Rdy On
REM Motor SP 0.00 rpm
Power 0.0 %
Figure 6-7 Setting the Control Panel to Local/Remote
Local Control If the converter is switched to local control, local operation from the ON/
OFF pushbuttons on the converter front door and from the CDP 312
control panel is possible. In local operation mode no remote control
command will be accepted.
Remote Control If the converter is switched to remote control, local operation from the
pushbutton on the front door of the control unit and from the CDP 312
control panel is disabled. All commands like close/open main circuit
breaker, start/stop or speed reference values are only received through
the remote control interface.
Emergency Off The local emergency off buttons on the front doors of the control unit(s)
remain active in local and in remote mode.
Start and Stop The converter can be started and stopped either manually from the local
Sequences control panels or from remote overriding control.

6.4.2 Start Sequence

If all preconditions are fulfilled the converter can be switched on by
pressing the local ON button.
Each INU can be started individually locally or from remote as soon as the
DC link is charged.
ARU Control INU Control
NOT RDY ON
- No fault
- Aux supply on
- Ground switch open
- ARU RDY ON
- WCU ok
- Doors closed
NOT RDY ON - etc. RDY ON
- No fault
- Aux supply on ON (Pushbutton)
Remote: ON
RDY ON Charge DC link

Close MCB
Close EXU contactor (SD)
- MCB closed
RDY RUN
Local: START
(CDP 312 ARU)
Remote:
automatically
RDY RUN
- Start Modulation Local: START

(CDP 312 INU)
Remote: RUN
RDY REF Start Modulation
RDY REF Operation according

to setpoint
Figure 6-8 Start Sequence with ARU

INU Control
NOT RDY ON
- No fault
- Aux supply on
- Gound switch open
- WCU ok
- Doors closed
- etc. RDY ON
ON (Pushbutton)
Remote: ON
Charge DC link
Close MCB
Close EXU contactor (SD)
RDY RUN
Local: START
(CDP 312 INU)
Remote: RUN
Start Modulation
Operation according
RDY REF
to setpoint
Figure 6-9 Start Sequence with LSU
6.4.3 Stop Sequence

Each INU can be stopped individually locally or from remote.
The converter can be switched off by pressing the local OFF button.


RDY REF RDY REF
Local: STOP
(CDP 312 INU)
Remote: RUN
Ramp down speed

Stop modulation
RDY REF RDY RUN
Local: OFF
(Pushbutton)
Remote: OFF
Open MCB (1st

INU)
Open EXU
contactor (SD)
(from master INU)
Stop modulation Discharge DC link
RDY ON RDY ON
Figure 6-10Stop and Off Sequence with ARU
INU Control
RDY REF
Local: STOP
(CDP 312 INU)
Remote: RUN
Ramp down speed

Stop modulation
RDY RUN
Local: OFF
(Pushbutton)
Remote: OFF
Open MCB (1st INU)

Open EXU
contactor (SD)
Discharge DC link
RDY ON
Figure 6-11 Stop and Off Sequence with LSU

6.4.4 Emergency Off Sequence

The converter is switched off immediately if the Emergency OFF button is
pressed.

RDY REF RDY REF
Emergency OFF
Open MCB (1st INU)

Stop modulation Open EXU
Stop modulation
Coast ramp down
NOT RDY ON NOT RDY ON
Figure 6-12 Emergency Off Sequence
6.5 Interface Configurations
6.5.1 General
The ACS 6000 can be integrated into all common industrial control envi-
ronments. Typically it is connected to the process control system via
fieldbus. The standard ACS 6000 provides all hardwired I/O signals to
protect itself. Optional I/Os can be provided if the transformer and motor
cannot be monitored directly by the process control system.
Normally the ACS 6000 is operated from the process control system.
The ACS 6000 can also be operated from the local control panel(s) or by
PC Tools (DriveWindow).
6.5.2 I/O Configurations for Single-motor Drives

The following three I/O configurations are possible:
• Standard configuration
The standard configuration includes the converter related functions
(i.e. interface to the MCB), the AF100 fieldbus communication inter-
face and the local control panel.

• Option CIW1
This option provides additional five I/O modules (S800 modules) with
predefined I/Os for transformer and motor auxiliaries.
• Option CIW2
This option provides a programmable AC80 controller with the same
I/O configuration as option CIW1.
Additionally, the five I/O modules can be replaced with other S800
modules. These I/Os can be allocated to specific functions,
depending on the user’s needs.
AF100 Bus
Fieldbus (e.g. Profibus)
Fieldbus (e.g. Modbus)

Service tool (*)
e.g. DriveWindow
ARU CBU INU TEU /COU WCU

/LSU)
Fieldbus
Adapters (*) Control
Panel
CIW1 (Option)
S800(*)
AC
DC
DC
AC
AMC3 Processor
Position /
speed
encoder (*) S800 S800
Standard I/O
(*) optional equipment Inverter/MCB/ WCU Customer

M Emergency off/ monitoring I /O (*)
charging
Figure 6-13 ACS 6000 Single-motor Drive with Option CIW 1
6.5.3 I/O Configurations for Multi-motor Drives

The following four I/O configurations are possible:
• Standard configuration
The standard configuration includes the converter related functions
(i.e. interface to the MCB), the AF100 fieldbus communication inter-
face and the local control panel.

• Option CIU1
This option corresponds to a multiple option CIW1. These additional
I/O modules (S800 modules) are placed in a separate cabinet (see
Chapter 5 - Description of Modules, Customer Interface Unit (CIU),
page 74).
• Option CIU2
This option corresponds to a multiple option CIW2. These additional
I/O modules (S800 modules) and AC80 are placed in a separate
cabinet (see Chapter 5 - Description of Modules, Customer Interface
Unit (CIU), page 74).
• Option CIUe
This option is used for engineered interfaces. The additional I/O
modules are placed in a separate cabinet (see Chapter 5 - Descrip-
tion of Modules, Customer Interface Unit (CIU), page 74).
AF100 Bus
Fieldbus (e.g. Profibus)
Fieldbus (Modbus)
Service Tool (*) Programming Service Tool (*) Service Tool (*)
e.g. DriveWindow Tool (*) e.g. DriveWindow e.g. DriveWindow
ARU CBU INU INU INU TEU / COU WCU CIU TEU / COU 2 TEU / COU 3
(LSU)
Fieldbus Fieldbus Fieldbus

adapters (*) CDP 312 adapters (*) CDP 312 adapters (*)
control CDP 312
control control
panel panel panel
AC80 / S800 (*)
AC DC DC DC AMC3 Processor AMC3 Processor AMC3 Processor
DC AC AC AC
Position/ Position/ Position/

Speed AC80 / S800 (*) AC80 / S800 (*) encoder S800 Speed
encoder S800 S800 S800
Speed encoder
Inverter 1 / MCB WCU Customer Customer Customer Inverter 2 I/O Inverter 3 I/O
M Emergency off / monitoring I / O (*) I / O (*) I / O (*)
Charging CIU2 CIU2 CIU2
M
M
(*): optional equipment
Figure 6-14 Typical ACS 6000 Multi-motor Drive with Option CIU 2

6.6 Fieldbus Interfaces
6.6.1 Fieldbus Types

The ACS 6000 control system includes AF100 fieldbus communication
interfaces to connect to the ABB Advant automation series. Optionally
fieldbus interfaces to most other standard process automation systems
are available.
The currently available fieldbus adapters are listed in the table below:
Table 6-1 Fieldbus Adapters
Fieldbus Adapter Type
Fieldbus Communication Interface (FCI) CI 8210
Profibus DP NPBA-12
Modbus NMBA-01
Modbus+ NMBP-01
6.6.2 Signals
Communication with the AMC3 controller is accomplished with datasets,
each containing 3 x 16 bit integers. Each dataset contains a standardized
set of process data. The content of the datasets must be programmed
accordingly in the remote process controller.
The following tables give an overview of basic signals that are transmitted
between AMC3 controller and the external process control system.
Note: The following tables are for general information only and should not
be used for engineering purposes. The project relevant signal and param-
eter tables depend on the final drive configuration and on the selected
control and communication devices.
Apart from these basic I/O signals, there are several sets of additional
data, such as alarm and fault data, setpoints, actual values, limitations etc.

Table 6-2 Basic Data Exchange between AMC3 and Process Control:
Analog and Binary Inputs
I/O-Type Target Value Description
Reference 1 INU Speed reference in rpm
Reference 2 INU Torque reference
Input bit 0 INU/ 1 Command to close MCB

ARU
0 Command to open MCB
Input bit 1 INU/ 1 –

ARU
0 Emergency OFF (Stop by coasting + MCB off)
Input bit 2 INU/ 1 –

ARU
0 Emergency STOP (Stop by emergency stop ramp)
Input bit 3 INU 1 Command for state "RDY REF" (converter running)
0 Normal stop (blocking of current controller)
Input bit 4 INU 1 Normal operation
0 Ramp generator output is set to zero (torque stop)
Input bit 5 INU 1 Enable speed ramp
0 Speed ramp is stopped, actual setpoint is frozen
Input bit 6 INU 1 Enable setpoint
0 Ramp generator input is set to zero (ramp stop)
Input bit 7 INU/ 1 Fault reset (at rising edge)

ARU
0 –
Input bit 8 INU 1 Accelerate to inching speed ref 1
0 Stop inching (brake as fast as possible)
Input bit 9 INU 1 Accelerate to inching speed ref 2
0 Stop inching (brake as fast as possible)

Analog and Binary Inputs (continued)
Input bit 10 1 AC80 control system is requesting to control the

drive
0 No control from remote
Input bit 11 1 Select external control location 2
0 Select external control location 1
Input bit 12 1 –
0 Process stop requested
Analog and Binary Outputs
Output word INU Actual motor speed which is used by the speed
controller, in rpm (integer: 20000= maximum
speed)
Output word INU Actual torque (integer: 10000= nominal torque)
Output bit 0 INU/ 1 Status "Ready to accept ON command"

ARU (ready to close MCB)
0 Not ready
Output bit 1 INU/ 1 Status "Ready to accept RUN command" (ready to

ARU start)
0 Not ready
Output bit 2 INU/ 1 Status "Ready to accept reference" (converter

ARU running)
0 Operation inhibited
Output bit 3 INU/ 1 Drive tripped

ARU
0 No fault
Output bit 4 INU/ 1 –

ARU
0 Emergency OFF active
(Stop by coasting + MCB off)

Analog and Binary Outputs (continued)
Output bit 5 INU 1 –
0 Emergency STOP active

(Stop by emergency stop ramp)
Output bit 6 INU/ 1 Switching ON is inhibited

ARU
0
Output bit 7 INU/ 1 Alarm or warning is active

ARU
0 –
Output bit 8 INU/ 1 Setpoint and actual value within tolerance

ARU
0 Actual value differs from setpoint
Output bit 9 INU/ 1 Drive in remote control mode (control by overriding

ARU system)
0 Drive in local control mode (CDP 312 panel or
DriveWindow)
Output bit 10 INU/ 1 Actual speed equals or exceeds limits

ARU
0 Actual speed within limits
Output bit 11 INU/ 1 External control location 2 selected

ARU
0 External control location 1 selected
6.7 Hardwired Process I/Os
6.7.1 S800 I/O Modules

The ACS 6000 uses the standard ABB Advant S800 I/O modules.
The internal signals of the converter, the external signals for converter
protection as well as I/O signals to and from external components are
connected to the control system by standard S800 modules.
An S800 I/O station consists of up to 12 I/O modules and an interface (TB
820 module bus modem or AC80 controller) to the AMC3 controller
(Figure 6-15). Each I/O module is plugged into a so called module termi-
nation unit which contains also the S800 module bus.

TB 820 Module Bus Modem Digital I/O Module Analog I/O Module
TU 830 Module Termination Unit (MTU) TU 831 Module Termination Unit (MTU)
Figure 6-15 S800 I/O Station with TB 820

Several S800 I/O stations can be connected to one AMC3 controller.
TB 820 Module Bus The TB 820 module bus modem provides a fiber optic serial interface to
Modem the AMC3 board, using the standard DDCS protocol. Internal coordination
between S800 modules is achieved with an internal bus (module bus).
AMC3 Controller DDCS
S800 I/O Station

TB 820
S800 Module Bus
Output Output Input
Figure 6-16 Interface Structure with S800 I/O Module and TB 820
AC80 Controller The TB 820 bus modem can be replaced by a programmable AC 80

controller (see Figure 6-17) which offers additional processor functionality
to handle application-specific tasks.

AMC3 Controller
Drivebus
DDCS /
S800 I/O Station
AC80
S800 Module Bus
Output Output Input
Figure 6-17 Interface Structure with S800 I/O Module and AC80
S800 I/O Modules Several types of standard S800 I/O modules are available (see Table 6-4).
Table 6-4 S800 I/O Modules
I/O Socket
Description
module module
DI810 16 channels, 24 VDC TU830

Digital input
DI820 8 channels, 120 VAC TU831
DO810 16 channels, 24 VDC TU830

Digital output
DO820 8 relay channels, 230 VAC TU831
AI810 8 channels, 0(4)…20 mA, 0…10 V TU830

AI830 8 channels, resistance TU830
Analog input
AI835 measurement (PT100) TU830
7+1 for thermocouples or mV inputs
Analog output AO810 8 channels, 0…20 mA TU830
S800 Sockets The sockets for the S800 I/O modules are called Module Termination Units
(MTU). Two different types are available:
• TU831 for relay output modules (250 VDC), and
• TU830 for all other modules (24/48 VDC).

6.7.2 Signals
The following tables provide an overview of standard signal interfaces.
Note: The following tables are for general information only and should not
be used for engineering purposes. The project relevant signal and para-
meter tables depend on the final drive configuration and on the selected
control and communication devices.
6.7.3 Standard Signals
Digital Input Signals

(Motor 1)
/Emergency OFF (loop)
/Emergency OFF (loop)
/Drive operation prevented
/Process stop

(Motor 2)
/Process stop motor 2

(Motor 3)

(Motor 4)


(Motor 5)

(MCB, Emergency Off)
/Emergency STOP
/Emergency STOP
Emergency STOP Reset (option)
Emergency OFF Reset (option)
MCB status OPEN
MCB status CLOSED
MCB (presignal & tripped & available)
Digital Output Signals

(MCB)
INU operation prevented (option)
MCB order CLOSE
MCB order OPEN 1
MCB order OPEN 2 a
/MCB order TRIP a
a. only one signal has to be used, depending on MCB type

Relay contact ratings:
• Permanent load: 230 VAC / VDC, 3 A
• Breaking power AC: 720 VA & cosϕ > 0.4
• Breaking power DC: 40 W

(Miscellaneous)
Motor space heater ON order

6.7.4 I/O with CIW 1 Option (Standard Software)
Analog Input Signals

Analog Input Signals
Ext. 24VDC power supply for all analog inputs (option)
External speed reference 1 [-10V...0V...+10V]
External speed reference 2 [-10V...0V...+10V]
Selectable AI Ch3 [-10V...0V...+10V]
Fail safe Emergency STOP [0V...+10V] (supervision)
Parameters for each channel:

• Scaling
• Minimum
• Value
• Filtering
• Inversion
• Offset

External ON request
External OFF request
External START request
External STOP request
A.) Negative (- rpm) SpeedReference request a

B.) Zero (0 rpm) SpeedReference request
C) Constant SpeedReference request
External RESET request
A.) Transformer supervision Flt/Alm a

B.) Transformer overtemperature Flt/Alm
C.) Drive RUN prevented (RUN Lock)

B.) Transformer overtemperature Flt/Alm
C.) Drive START permission (no effect if Started)
Transformer oil level supervision Flt/Alm

B.) Transformer gasRelay Flt/Alm

B.) Transformer gasRelay Flt/Alm
Motor water supervision (condence water/cooler leakage) Flt/Alm a

A.) Motor supervision Flt/Alm a

B.) Motor overtemperature Flt/Alm
A.) Motor supervision Flt/Alm a

B.) Motor overtemperature Flt/Alm
A.) Motor bearing supervision Flt/Alm a

B.) Motor bearing vibration Flt/Alm
A.) Motor bearing supervision Flt/Alm a

B.) Motor bearing vibration Flt/Alm
a. Selection with parameter
Analog Output Signals

Analog Output Signals
Selectable AO1 (n_act)

[-20mA...+20mA
-10V...+10V]
Selectable AO2 (P_act)

[-20mA...+20mA
-10V...+10V]
Selectable AO3 (T_act)

[-20mA...+20mA
-10V...+10V]
Selectable AO4 (Is_act)

[-20mA...+20mA
-10V...+10V]

• AMC table group + index selection
• Inversion
• Offset
• Filtering
• Scaling

Selectable DO1 (Ready ON)
Selectable DO2 (Ready RUN)
Selectable DO3 (Ready REF)
Selectable DO4 (Fault)
Selectable DO5 (Alarm)
Selectable DO6 (Emergency STOP)
Selectable DO7 (ON command)
Selectable DO8 (zero speed)


• AMC table group+index selection
• Inversion
• Bit selection
Relay contact ratings:
• Permanent load: 230 VAC / VDC, 3 A
• Breaking power AC: 720 VA & cosϕ > 0.4
• Breaking power DC: 40 W
PT100 Analog Input

Signals PT100 Analog Input Signals
PT100 Ch1 (Main transformer temperature 1)
PT100 Ch4 (Motor winding temperature 1)
PT100 Ch7 (Motor additional temperature 1)
PT100 Ch8 (Motor additional temperature 2)

• Signal name selection
• Alarm
• Fault limit
6.7.5 I/O with CIW 2 Option (Project Specific SW) Controlled by AC80 Controller
The CIW 2 option includes five S800 I/O modules. The module types and
the default I/O allocation is the same as with option CIW 1.
As additional option it is possible to replace the five I/O modules with other
S800 modules and the I/Os can be allocated to specific functions,
depending on the user’s needs.


Chapter 7 - Standard Control and Protection Functions
7.1 General
The ACS 6000 control and protection system is configured and custom-
ized with a set of application parameters. These parameters are used to
activate or to adjust specific control functions.
Parameters can be modified either with the CDP 312 control panel
(supplied with the converter) or with a PC and the DriveWindow software
package.
The most relevant control, monitoring and protection functions which are
set with the parameters mentioned above are discussed in this chapter.
These functions are integrated in the control concept which is described
in Chapter 6 - Control System and Process Interfaces.
7.2 Motor Control Functions
7.2.1 Speed Control Features
Accurate Speed The speed controller is based on a T (%) nact-nref

TN nN
Control PID algorithm.
Tload
The steady state speed control error is 100
around + 0.1% (without pulse
encoder, see also Appendix A - Tech-
nical Data, Static Speed Inaccuracy, 0
n
page 153) of motor nominal speed, t (s)
0.01%sec
which satisfies most industrial appli-
cations. TN = rated motor torque
nN = rated motor speed
Dynamic speed control error is typi- nact = actual speed
cally + 0.2…0.5 %sec. at 100% load nref = speed reference
torque step. The dynamic speed error
depends on speed controller tuning.
Figure 7-1 Control Features
Acceleration and The ACS 6000 provides Max

Speed Reference
Deceleration Ramps user selectable acceleration
Speed Reference
and deceleration ramps. It is 0 change limited by
linear ramp
possible to adjust accelera- Speed reference
tion and deceleration times change limited by
S-curve ramp
and to select between
different ramp shapes: Acceleration
time
Ramp shape time

• S-curve ramps are ideal for applications, where a smooth transition

from one speed to another is required.
• Linear ramps for converters which require long acceleration/deceler-
ation periods and where the characteristics of S-curve ramping are
not required.
Oscillation Damping With some processes, operating a motor at critical shaft speeds cannot be
avoided and solving oscillation problems by redesigning an installation is
an expensive and time consuming task. In these cases, oscillation
damping can be used to minimize and eliminate mechanical resonances.
A finite impulse response filter (FIR) is used to eliminate torsion oscilla-
tions. The filter uses speed error as an input. A bandpass filter searches
for certain frequencies and calculates a sine wave which is added to the
torque reference; it is based on the following parameters:
• Resonance Frequency: The mechanical resonance frequency which
needs to be eliminated
• Phase Shift: The phase shift between the (resonance) frequency
present and the generated cancellation signal (typically slightly less
than 180°)
• Proportional Gain: The gain which is used in generating the cancella-
tion signal.
Accurate Torque By applying torque reference instead of speed reference, the ACS 6000
Control maintains a specific motor torque value; the speed will adjust automati-
cally to maintain the required torque.
For details, see Chapter 3 - Key Technologies, Direct Torque Control,
page 37.
Speed and torque performance figures meet or exceed the requirements
of IEC 61800-4.
Speed Control By setting the appropriate parameters, maximum and minimum limits can
Limitations be defined for speed and torque output.
7.2.2 Direct Torque Control Features
Direct Torque Control By setting the appropriate parameters, maximum and/or minimum limits
Related Limitations can be defined for:
• Frequency
• Current
• Inverter overload
• Load angle
• DC Voltage

Flux Optimization Flux optimization by dynamic field weakening improves the dynamic
performance in the highspeed range of the ACS 6000. At low speeds on
the other hand, flux is increased by up to 20%.
Motor Model The adaptive motor model produces exact actual values of torque and flux
based on measured motor current and DC link voltages.
Excitation Control The excitation current is controlled in a way that the power factor of
synchronous motors is 1.
Speed and Rotor Rotor speed and position can be monitored continuously for synchronous
Position motors to improve static and dynamic performance of the motor control
loop. For asynchronous motors, speed monitoring is available.
7.3 Active Rectifier Control Functions
DC Voltage Control The voltage of the DC link is stabilized by DC voltage control inside the
active rectifier unit, minimizing the impact resulting from disturbances
within the converter or the mains supply.
Reactive Power Reactive power control for the active rectifier unit is available as option. It
Control is used to maintain a power factor of 1 in the mains supply. With reactive
power compensation, cos ϕ can be controlled to any value within the
range of +/- 0.8. The supply voltage level and supply voltage fluctuation
have to be considered for the adaptation of the reactive power control.
7.4 Application Control Functions
7.4.1 Motor Related Functions
Load Share Control Load share control is used for applications with two separate motors
where the shafts are coupled to each other by gearing, chain, belt, process
etc. By means of load share control the load can be evenly distributed
between the drives.
Positioning Control The positioning control function is used to turn the motor shaft to a refer-
ence position. This feature is mostly required for changing work rolls in a
rolling mill (metal applications).
7.4.2 Network Related Functions
Main Circuit Breaker The main circuit breaker should be closed by the converter only. This
Control means that a closing request from the customer is sent to the ACS 6000.
The actual closing command is then released from the converter to the
main circuit breaker after charging the converter DC link capacitors.

Main Circuit Breaker All opening and closing commands to the main circuit breaker are moni-
Control Fault tored for time out. If the main circuit breaker does not change its status
within a preset time, the main circuit breaker is tripped.
Preconditions for charging and for closing the main circuit breaker are:
• No protection trip is active
• No emergency off or stop is active
• The grounding isolator is open
• The input isolator (optional) is closed
• Main circuit breaker must be in operating position (not in test position)
• All cabinet doors are closed
• Water cooling unit is running and conductivity of the cooling water is
within limits.
The signal from the converter to the main circuit breaker to close can be a
continuous signal or a single pulse. If this status feedback does not arrive
after a preset time, the close command is reset and a main circuit breaker
trip is initiated.
Conditions for opening the main circuit breaker are:
• Main circuit breaker open command (off command to active rectifier
unit) is given either from local or from remote control
• The emergency off is active (hardware signal or requested by the
overriding control). The hardware signal directly activates the main
circuit breaker tripping coil.
• A critical fault is detected by active rectifier unit or inverter unit
• The emergency stop sequence is accomplished in an inverter unit
and requests opening of the main circuit breaker.
If the signal from the converter to the main circuit breaker to open is a
single pulse signal, it is reset upon receiving the status feedback main
circuit breaker OPEN from the switch gear. If this status feedback does not
arrive after a preset time, the tripping coil of the main circuit breaker is acti-
vated.
Several external main circuit breaker trip commands can be integrated
into the hardwired tripping loop (e.g. transformer and motor monitoring
relays, process trips, etc.)
DC Link Control The DC link control monitors the DC voltage level at which main circuit
breaker closing is enabled. It also monitors the DC voltage level at which
the DC link is considered discharged and charging and discharging time
outs, as well as other monitoring functions regarding the charging of the
DC link.

7.5 Diagnostics
Actual Signal Three signals can be displayed simultaneously on the control panel.
Monitoring
The most significant signals are:
• ACS 6000 output frequency, current, voltage and power
• Motor speed and torque
• DC link voltage
• Active control location (local / remote)
• Reference values
• Cooling water temperature, pressure and conductivity
• Digital I/O and analog I/O status.
Fault History The fault history contains information on the 64 most recent faults
detected by the ACS 6000. Faults are displayed as a text message.
7.6 Standard Protection Functions
7.6.1 General
All relevant system quantities within the ACS 6000 are continuously moni-
tored by the control system. Preprogrammed protection functions ensure
that these quantities remain within certain limits, in order to maintain safe
operation of the converter. These internal functions are not programmable
by the user. Optionally the ACS 6000 offers the processing of standard
and customer specific fault signals from external equipment. They can be
activated and adjusted by parameter settings.
If a disturbance occurs in the converter or in related equipment, it will be
indicated with an error message on the CDP 312 control panel or, as alter-
native, on the DriveWindow error display.
Two error message levels are used in the ACS 6000:
• Alarm (warning): an alarm does not shutdown the drive. However, a
persisting alarm condition can often lead to a fault, if the condition
causing the alarm is not corrected.
• Fault: a fault always shuts down either the affected inverter or the
whole drive. The type of shutdown depends on the origin of the fault .
Several fault classes are distinguished. In case of a fault in the ARU, INU
or an external device, the drive trips by blocking the IGCTs. In case of a
severe internal fault the ACS 6000 protects itself by turning on all

switching devices simultaneously. This protection firing, combined with a

fast main circuit breaker, allows a fuseless converter design.
If an ARU initiates a trip, all INUs connected to the same DC bus trip as
well and the main circuit breaker is opened.
If an INU initiates a trip, the main circuit breaker does not necessarily
open. Depending on the severity and the type of fault, the main circuit
breaker remains closed and only the affected INU trips (an overriding
control system connected to the drive may stop the other INUs as well, if
required).
7.6.2 Internal Protection Functions

Internal protection functions monitor the relevant system quantities. These
quantities are calculated from the measurements supplied by the standard
converter instrumentation.
Motor Stall The stall protection function is used

to prevent the motor and/or the
Torque
inverter from overheating, or the
motor from pulling out. The Stall region
ACS 6000 protects the motor if a stall Tm.a
condition is detected. The monitoring
limits for stall frequency (speed) and
stall time can be set by the user. The
user can also select whether the stall
function is enabled and whether the Stall f (Hz)
converter responds with an alarm or Frequency
a trip when a stall is detected.
Figure 7-2 Stall Region of the Motor

The protection is activated if all of the following conditions are fulfilled
simultaneously:
1 Output frequency is below the set stall frequency.
2 Actual torque exceeds stall torque limit (torque limit
level can be set by the user).
3 Frequency and torque levels from conditions 1 and 2
have been present for a period longer than the set
stall time.
Overspeed Motor speed (as determined by the motor model) is monitored. If the motor
speed exceeds the maximum permitted level which is user adjustable, a
trip is initiated.
Overfrequency If the frequency of a motor exceeds a preset level, the corresponding

converter will be tripped.

Undervoltage The DC link voltage is monitored on active rectifier unit and inverter unit
side by means of a voltage measurement between DC(+) and DC(-). If the
voltage drops below a preset level, an undervoltage trip is initiated.
Overvoltage The voltage levels of DC(+) to DC(NP) and DC(-) to DC(NP) are moni-
tored. If one voltage rises above a preset level, an overvoltage trip is initi-
ated.
Overvoltage protection is implemented both in software and in hardware,
to provide ultimate reliability to the converter.
Neutral Point Voltage The symmetry between the DC(+) to DC(NP) and the DC(-) to DC(NP)
Symmetry voltages is monitored.
Charging / Discharging The intermediate DC link voltage is monitored while charging and
Fault discharging the capacitors. If the voltage does not reach a certain level
within a preset time frame, a fault signal is initiated.
Phase Loss Inverter phase currents are monitored. In case of loss of a phase, a trip is
initiated.
Overcurrent Inverter phase currents are monitored. If a preset level is exceeded, a trip
is initiated. This protection is implemented both in software and in hard-
ware.
Converter Short Circuit A trip is initiated in case of a short circuit.
Ground Fault A ground fault is detected in two ways:

• The neutral point voltage is monitored against earth. If the measured
values are higher than the acceptable level, a trip is initiated.
• The sum of the inverter phase currents is monitored. If the result does
not equal zero, a trip is initiated.
DC Link Short Circuit A trip is initiated in case of a short circuit.
Excitation Protection With synchronous motors the excitation circuit is protected against
• Overcurrent
• Overload (SW monitoring function)
• Supply network disturbance
• Earth fault
Cooling Circuit The operating condition of the cooling circuit is monitored. If any of the
monitored signals like temperature, pressure or conductivity of the water
exceed a preset limit, an alarm or (if the condition persists) a trip is initi-
ated. In addition to these functions, the status of the cooling water pumps
and the water level in the expansion vessel are monitored.
A flow measurement is included in the water treatment circuit.

Communication The status of all communication links is monitored. If a fault is detected, a

Monitoring trip is initiated.
ARU Protection If the converter is equipped with an active rectifier unit, the following
Functions protection functions are included:
• Network undervoltage (alarm and fault signals)
• Network overvoltage (alarm and fault signals)
• Network frequency deviation (alarm and fault signals).
7.6.3 External Protection Functions

Inputs from additional external protection devices are monitored.
Main Circuit Breaker Inputs are provided for main circuit breaker monitoring functions (see Main
Circuit Breaker Control Fault, page 118).
Motor(s) Optional inputs for collective motor and bearing alarms and faults are
provided (optional customer interfaces, see Chapter 6 - Control System
and Process Interfaces, Hardwired Process I/Os, page 106).
Supply Transformers Optional inputs are provided for collective transformer alarm and fault
(optional customer interfaces, see Chapter 6 - Control System and
Process Interfaces, Hardwired Process I/Os, page 106).
7.6.4 Manually Initiated Protection Functions
Hardwired Safety A hardwired safety circuit with redundant safety and timer relays monitors
Circuit essential safety functions:
• Door interlocking
• Position of the earth isolator in the capacitor bank unit
• Emergency off switch(es) on the control cabinet doors
If any of the contacts of the protection devices opens, the safety circuit
shuts down the drive.
Manual Emergency The following inputs for manual emergency shutdown are provided:
Shutdown
• Emergency off:
The main circuit breaker is opened immediately.
• Emergency stop:
The motors are ramped down to zero speed as fast as possible and
the main circuit breaker is opened.
Process Stop A digital input is provided per motor to connect a process stop signal.
If the process stop input is opened, the affected motor is stopped. This is
a software function and by setting a parameter, the type of stop can be
selected:

• Torque limit
• Ramp
• Coast stop.
Note: The process stop does not replace an emergency function.
Operation Prevention A digital input per motor is provided to connect an operation prevention
signal.
If the input is opened, the corresponding motor cannot be started.
7.7 Other Features
ACS 6000 Information The ACS 6000 software version, the production date of the individual
version, and the serial number can be displayed.
Parameter Lock The user can prevent unwanted parameter adjustment by activating the
parameter lock.
7.8 Customer Specific Options
Information on additional user specific options can be found in Chapter 8

- Options.


Chapter 8 - Options
8.1 Converter Hardware
Process I/Os • Standardized hardwired motor and transformer monitoring

• Customer specific hardwired I/Os
• Connection to process control
Fieldbus Interfaces, page 103.
AC Disconnectors • Motor operated disconnector motor side

• Ground disconnector
• Disconnector
• Disconnector with grounding of motor
• Disconnector with grounding of converter
• Motor operated disconnector transformer side
• Ground disconnector
• Disconnector
• Disconnector with grounding of transformer
• Disconnector with grounding of converter
Note: The taken choice has a direct impact on the drive configuration.
Cabinets • Cable entry from top (power and/or control cables)

• Water connection from top
• Bottom frame
• Cable glands (ROX - modules)
Note: ROX gland frame is standard supply.
• Higher IP rating (IP 44, IP 54)
• Non standard cabinet color
• Language of warning labels
• Customer specific labelling

Chapter 8 - Options
Instrumentation • Insulation resistance measurement device

Monitoring device for insulation condition in medium voltage circuit
with programmable alarm level.
• Pulse encoder interface module (NTAC board) for rotor speed mea-
surement
• Gray encoder board (GRB) for rotor position measurement
• Fast I/Os (NBIO-22)
Cooling System • High raw water pressure (10 .. 16 bar)

• Leakage sensor
• Raw water valve (not in WCU)
• Raw water filter (not in WCU)
• Flexible raw water connection
• External cooling water temperature monitoring
• Titanium heat exchanger
• No internal heat exchanger for fin fan cooler or chiller
Ambient Conditions • Extended altitude range

• Extended cooling water temperature range (10 °C .. 36 °C)
• Extended ambient temperature range (5 °C .. 45 °C)
• Extended standstill temperature range
• Glycol in deionized water (requires output power
derating)
• Glycol in raw water (requires output power derating)
• Cabinet space heaters (approx. 100 W/m)
Enhanced Corrosion • Nickel coated busbars

Protection
• All circuit boards varnished
Excitation • Brushless excitation

For details see Chapter 5 - Description of Modules, Excitation Unit
(EXU), page 83.
8.2 Converter Software
• Adjustable power factor

Optionally the ARU is able to compensate reactive power generated
by other loads connected to the same network. The MVA ratings of
the converter remain unchanged. This option requires further system
calculations.

Chapter 8 - Options
• Programming of customer specific I/O configuration

For options CIW2, CIU2 and CIUe according to Chapter 6 - Control
System and Process Interfaces, Interface Configurations, page 100.
• Language of panel messages (standard language is English)
8.3 Service and Diagnostics
• Spare parts
3 sets of spare parts are available:
• Minimum package for commissioning
• Medium package for 1 .. 2 years of operation
• Maximum package for 3 .. 5 years of operation.
• Set of special tools for power semiconductor replacement
• Tools for stack disassembly
• Trolley for exchange of phase modules
• Water cooling
• Pump to fill the water circuit
• Make-up water
• Earthing sets
• PC Tools - DriveWindow
DriveWindow offers several advanced, yet easy to use tools for
commissioning and controlling the ACS 6000:
• The parameter and signal tool with a full set of device
specific data either in online or offline mode to check,
study and change the parameters
• The monitor tool as a graphic interface for monitoring
digital and analog signals
• The data logger as a versatile way of tracing fast and
accurate events
• The fault logger displaying a fault history
• The application tools presenting the pin values in
order to debug application software and force
constants.
• DDCS branching unit for DriveWindow to access all AMC3 controllers
from one location
• Service contracts

Chapter 8 - Options
8.4 Marine Version
The marine version includes a set of options:

• Extended cooling water temperature
• Extended ambient temperature
• All boards varnished
• Marine cabinets
• Heaters
• Base frame with vibration damping material
• Leakage sensor.
8.5 Transportation, Installation and Commissioning
• Sea freight packing (Incoterm EXP)

• Make-up water
• Erection
• Commissioning
8.6 Training
• Operation and maintenance training

The participants will be taught how to operate, maintain and trouble-
shoot the ACS 6000 drive system.
• Service and commissioning training
The participants will learn how to commission, operate, maintain and
troubleshoot the ACS 6000 drive system including the replacement of
circuit boards and power components.
8.7 Testing
• Additional non-standard tests

• Customer witness test
• Additional external tests
• Production supervision

Chapter 8 - Options
8.8 Documentation
• Language of user’s manual (standard language is English)

• User’s manual on CD-ROM

Chapter 8 - Options

Chapter 9 - Requirements for System Components
9.1 General
This chapter describes the most important system components which are
not included in the scope of supply. In addition, the ACS 6000 specific
requirements for these components are defined.
9.2 Main Circuit Breaker
The main circuit breaker is one of the most important protection devices of
the whole fuseless designed drive system.
The main circuit breaker should preferably be a SF6-gas insulated circuit
breaker or a vacuum type breaker. The main circuit breaker has to be
specified according to the rated primary voltage and current of the trans-
former and shall comply with IEC Publication 56 and ANSI c37.09.
9.2.1 Maximum Breaking Time

A maximum breaking time of 60 ms has to be guaranteed in order to
ensure the correct operation of the ACS 6000 under fault condition. (The
breaking time consists of opening time and arcing time.)
The internal circuit breaker control - including the auxiliary release - must
be redundant. Both paths must be capable to break the fault current within
the specified time of 60 ms.
The ACS 6000 control part guarantees a maximum additional delay time
of 15 ms. This way the required overall response time of less than 75 ms
can be achieved.
9.2.2 Control Interface
Commands The circuit breaker is controlled by the following three signals:

• Close command
• Open command
• Trip command
Note that the maximum breaking time of 60 ms applies to both, open and
trip command.

Status Signals The ACS 6000 control expects the following status signals of the main
circuit breaker:
• Circuit breaker open
• Circuit breaker closed
• Circuit breaker pre-trip, tripped or not available
The main circuit breaker standard auxiliary voltage is 110 VDC ±10%.
Optionally 220 VDC, 230 VAC or 120 VAC are also possible. ABB recom-
mends to use DC due to the breaking time requirements.
9.2.3 Main Circuit Breaker Equipment

The following aspects have to be considered in the main circuit breaker
specification in order to assure the desired drive system functionalities.
• Two opening coils are recommended. Optionally one opening coil can
be left out by tripping the main circuit breaker via the undervoltage
coil. However, the maximum allowed breaking time of 60 ms must not
be exceeded.
• Five auxiliary contacts are recommended. In the alternative main
circuit breaker connection scheme (see Figure 9-2) four auxiliary
contacts are used.
• The main circuit breaker must be equipped with an overcurrent
protection relay. Overcurrent should be detected on the primary and
secondary side of the main transformer. The relay must tolerate
transformer inrush currents without tripping.
• The main circuit breaker is exclusively closed from the ACS 6000
control. A local main circuit breaker close command button must not
be connected.
• Auto-reclosing functionalities must be avoided.

9.2.4 Main Circuit Breaker Connection Schemes

MCB Order MCB Order MCB Order
24VDC Close Open Trip ACS 6000 COU
Safety Chain Master Master Master
+ Emerg. Off COU COU COU
(NC) DO810 DO810 DO810
INU 1 INU 1
DI810 DI810
/MCB presignal_tripped_not MCB Status
available CLOSED
MCB Order Open
Interface board INU 1
INU1 Relay DI810
OEI- Relay Relay Relay
FO K3 MCB Status
board K1 K2 K4
Undervoltage OPEN
Closing Coil 1 Opening Coil 1 Opening Coil 2
Coil
0V
*) K1 K2 K3 K4
E-Off E-Off E-Off
Not used
MCB Aux Voltage
Manual Close I>>

Forbidden to use I>
External
Not connected Overcurrent Manual
trip signals
X) Open
A B C
A B C
YC YO1 YO2 YU
Closing Opening Opening Undervoltage
coil coil1 coil 2 coil
N
X) automatic decoupling under transformer energisation

High voltage switchgear
*) for relay contact ratings see Chapter 6 - Control System and Process Interfaces, Digital Output Signals, page 111
Figure 9-1 Recommended Circuit Breaker Connection Scheme

24VDC MCB Order Close MCB Order Open MCB Order Trip ACS 6000 COU
Safety Chain
+ Emerg. Off (NC) Master COU Master COU Master COU
DO810 DO810 DO810
INU 1 INU 1
DI810 DI810
/MCB presignal_tripped_not MCB Status CLOSED
MCB Order Open available
Interface board INU 1
INU1 Relay DI810
OEI- Relay Relay Relay
K3 MCB Status
FO board K1 K2 K4
Undervoltage OPEN
Closing Coil 1 Opening Coil 1 Opening Coil 2
Coil
0V
*) K1 K2 K3 K4
E-Off E-Off E-Off
Not
used
MCB Aux Voltage
Manual Close I>>

Forbidden to use I>
External
Not connected Overcurrent Manual
trip signals
X) Open
A B
A B
YC YO1 YU
Closing coil Opening coil 1 Undervoltage coil
N
X) automatic decoupling under transformer energisation

High voltage switchgear
*) for relay contact ratings see Chapter 6 - Control System and Process Interfaces, Digital Output Signals, page 111
Figure 9-2 Alternative Main Circuit Breaker Connection Scheme
9.3 Main Transformer for ARU
The ACS 6000 converter is fed from a main transformer providing suffi-
cient impedance to limit line harmonics and short circuit currents to
acceptable levels (For details on the voltage shape applied to the trans-
former secondary winding refer to Chapter 3 - Key Technologies, Figure
3-7). Oil immersed or dry type transformers can be used. Between main
transformer and converter a maximum cable length of 300 m (984 ft.) is
allowed.
The transformer design and testing must comply with IEC 60076,
IEC 60146-1-3 and IEC 61378-1.

9.3.1 Transformer Windings

In case of multiple rectifier modules, the primary windings are connected
in series. In case of two ARU modules, the secondary windings are
connected in star and delta. With three ARU modules, the transformer
secondaries are connected in star and zig-zag. In this way an optimum
phase shift is achieved. For details see Figure 9-3.
Mains Mains Mains
ARU ARU ARU ARU ARU ARU
Single ARU Double ARU Triple ARU
Figure 9-3 Main Transformer Windings (ARU)
9.3.2 Technical Data

The requirements for the main transformer are:
• Insulation voltage for secondary side: 11.5 kV peak (phase to phase)
• Maximum dV/dt applied to transformer secondary side: 3 kV/µs
• Nominal secondary side voltage: 3.16 kV
• Supply voltage tolerance: +/- 10%
• Tapping: 2 * +/- 2.5% no-load tap changer is recommended
• Short circuit impedance: minimum requirement 15% based on
9 MVA.

9.4 Main Transformer for LSU
The ACS 6000 converter is fed from a main transformer providing suffi-
cient impedance to limit line harmonics and short circuit currents to
acceptable levels. Oil immersed or dry type transformers can be used.
Between main transformer and converter a maximum cable length of
300 m (984 ft.) is allowed.
The transformer design and testing must comply with IEC 60076,
IEC 60146-1-3 and IEC 61378-1.
9.4.1 Transformer Windings

If one LSU is connected, a three-winding transformer is needed (see
Figure 9-4). The primary winding is connected in star, the secondary wind-
ings are connected in star and delta. If two LSUs are connected, a 24-
pulse scheme with two independent three-winding transformers is
possible.
An earthed screen must be provided for capacitive decoupling of high
voltage and low voltage windings.
Earthed screen Earthed screen
LSU LSU LSU
12-pulse Configuration 24-pulse Configuration
Figure 9-4 Main Transformer Windings (LSU)

9.4.2 Technical Data

The requirements for the main transformer are:
• Nominal secondary side voltage: 2*1.725 kV or 2*1.65 kV
• Supply voltage tolerance: +/- 10% resp. +15% .. -10% (-5%.. -10%
with derating)
• Tapping: 2 * +/- 2.5% no-load tap changer is recommended
• Minimal short circuit impedance: 8% based on 9 MVA.
9.5 ARU Synchronization Transformer
9.5.1 Requirements for Synchronization Transformers

The minimum required accuracy class is 1,0 (voltage error ±1,0%, angle
error ±40’).
The rated burden for the transformer is 50 VA. If the transformer is
connected according to the second scheme shown in Figure 9-6, the rated
burden for the auxiliary windings needs to be higher.
The rated primary voltage level is given by the network voltage level. The
secondary side voltage has to be 100 V (measuring voltage level).
9.5.2 Two Possible Measurement Connections

Two different connecting schemes are proposed to measure the three-
phase synchronization voltages using one-phase transformers.
In the first scheme, the 3-phase mains voltage is measured using V-
connected transformers (Figure 9-5). With this scheme, only two trans-
formers are needed.
Fuses recommended
M
E
A B b a 100V A
100V S Recommended
U line to line
100V
R voltage: 100 V
I 100V 10%
N
A B b a G
Primary Secondary
L1 L2 L3
Figure 9-5 Two One-phase V-connected Voltage Transformers

The second possibility is to measure the phase voltages with three one-
phase transformers (Figure 9-6) or with a three-phase five-pole trans-

former. To avoid hazardous resonances between primary winding induc-

tances and system capacitances, a separate damping winding (auxiliary
earth fault winding) is needed.
Fuses recommended
dn M
E
A N da n a 100V A
100V
S
dn U
A N da n a 100V R
I
dn N
A N da n a G
Primary Auxiliary Secondary
L1 L2 L3
Figure 9-6 Three One-phase Voltage Transformers in Wye Connection

(Auxiliary Windings in Open Delta)
The damper winding is in open delta and is connected to a resistor (R in
Figure 9-6). In a normal network with an open delta voltage of 100 V:3
(with full one-phase network earth fault, the open delta voltage is 100 V),
a suitable value for R is about 47 Ω (200 W).
For networks containing large capacitor banks or feeding large arc
furnaces, a smaller resistor value is recommended (24 Ω, 400 W).
9.6 Excitation Supply
The voltage for the excitation system is supplied by a separate feeder

transformer (3-phase 400 VAC, as option: 690 VAC). Transformer ratings
depend on the motor data.
In case of multiple motors, one common medium to low voltage trans-
former can be used for several excitation units. In this case, a separate
feeder transformer must be added for each excitation unit in order to
provide sufficient commutation inductance according to Figure 9-7.

Excitation supply Excitation supply
Option A: Option B:
EXU EXU EXU EXU EXU EXU
Figure 9-7 Excitation Transformer Schemes for Multi-motor Drives
9.7 Synchronous Motor Requirements
Synchronous motors used in combination with ACS 6000 are Salient Pole
synchronous motors. Insulation requirements are higher than for motors
used in direct on line operations. For their thermal design the harmonic
content in the motor current has to be taken into consideration.
The synchronous motor has to be specified according to IEC 60034.
9.7.1 Windings
If the synchronous motor is supplied by more than one inverter unit,
parallel winding systems without phase shift are required.
9.7.2 General Motor Characteristics

• Nominal motor voltage: 3000 ... 3300 V depending on supply type
and application
• Minimum insulation level: 7.2 kV (for 3.3 kV nominal converter output)
• Maximum dV/dt: 3 kV/µs at motor terminals
• Maximum field weakening ratio: 1:5

9.7.3 Encoders
Shaft speed and position are essential in order to control synchronous
motors. Speed and position can either be measured or estimated by the
drive’s control system depending on the process requirements.
Encoders improve the static and dynamic speed accuracy. Figures are
shown in Table 9-1.
Table 9-1 Typical Static and Dynamic Speed Accuracy
With Encoder Without Encoder
Static speed inaccuracy +/- 0.01% +/- 0.1%

Dynamic speed inaccuracy 0.2 .. 0.5 %s 0.5 .. 1.0 %s
9.7.4 Bearings
Motor bearings must be insulated. The rotor shaft must be earthed via
earthing brush to the local earth in order to prevent current circulation on
the mechanical system (process) connected to the motor. Earthing needs
to be designed for high dV/dt.
9.7.5 Excitation
DC excitation with brushes and brushless AC excitation is possible. For
further details on the excitation system see Chapter 5 - Description of
Modules, Excitation Unit (EXU), page 83.
9.8 Asynchronous Motor Requirements
Asynchronous motors used in combination with ACS 6000 are squirrel

cage induction motors. Insulation requirements are higher than for motors
used in direct on line operations. For their thermal design the harmonic
content in the motor current has to be taken into consideration.
The asynchronous motor has to be specified according to IEC 60034.
9.8.1 Windings
If the asynchronous motor is supplied by more than one inverter unit,
parallel winding systems without phase shift are required.

9.8.2 General Motor Characteristics

• Nominal motor voltage: 3000 ... 3300 V depending on supply type
and application
• Minimum insulation level: 7.2 kV (for 3.3 kV nominal converter output)
• Maximum dV/dt: 3 kV/µs at motor terminals
• Field weakening operation possible above 7.2 Hz
9.8.3 Encoders
Shaft speed and position are not required. Nevertheless encoders
improve the static and dynamic speed accuracy. Figures are shown in
Table 9-2.
Table 9-2 Typical Static and Dynamic Speed Accuracy
With Encoder Without Encoder
Static speed inaccuracy +/- 0.01% +/- 0.1%
Dynamic speed inaccuracy 0.2 .. 0.5 %s 0.5 .. 1.0 %s
9.8.4 Bearings
Motor bearings must be insulated. The rotor shaft must be earthed via
earthing brush to the local earth in order to prevent current circulation on
the mechanical system (process) connected to the motor. Earthing needs
to be designed for high dV/dt.
9.9 Selection of Power Cables
9.9.1 Power Cable Dimensioning

In order to dimension power cables exactly, the following aspects have to
be considered:
• Loading of cables
• Specifications of the cable manufacturer.
• Method of installation
• Voltage drop due to cable length
• Local regulations.
The drive specific cable requirements are described in the following
sections.

9.9.2 Cables for ARU and INU
General Requirements Power cables on the supply side and on the motor side have to meet the
following requirements:
• Screened cables are mandatory (EMC requirements).
• Cables with 3 individually shielded conductors and common armor
are recommended. If the length of the cables does not exceed 100 m,
single-core cables can be used and installed in groups of three.
• It is recommended to use copper conductors to minimize the dimen-
sions of the cables (smaller bending radius). If aluminium cables are
used, specially coated terminations are required.
• The maximum cable length must not exceed 300 m (900 ft.).
• The cable cross section shall be selected that the number of parallel
conductors is minimized. It is recommended to use cables with
conductor cross section of 3 x 240 mm2 and a shield of 3 x 35 mm2.
• If the cross section of the cable screens is less than 50% of the cross
section of one phase conductor an additional grounding wire along
the power cable is needed. It prevents screen overloading caused by
potential differences in the plant.
• A typical example of a cable that meets all requirements is shown in
Figure 9-8.
Figure 9-8 Typical Cable Example
Insulation • Cables shall be designed for 6 kV nominal / 10 kV peak voltage.

Requirements
• dV/dt requirements: 3 kV/µs
• Recommended insulation materials are EPR (Ethylene-Propylen-
Rubber) and XLPE (Cross-linked Poly-Ethylene).
Typical cable connection schemes can be found in Chapter 10 - Installa-
tion Guidelines, Figure 10-3 and Figure 10-5.

9.9.3 Cables for LSU
General Requirements The same general requirements as for ARU / INU apply. See General
Requirements, page 142.
Insulation • Cables shall be designed for 3.3 kV nominal / 6 kV peak voltage.

Requirements
Typical cable connection schemes and installation guidelines can be
found in Chapter 10 - Installation Guidelines, Figure 10-4.
9.9.4 Cables for BCU
General Requirements The same general requirements as for ARU / INU apply. See General
Requirements, page 142.
Insulation • Cables shall be designed for 6 kV nominal / 10 kV peak voltage.

Requirements
• dV/dt requirements: 3 kV/µs
9.10 Control Cabling
Control Cables Control cables should be provided in accordance with Table 9-3. Cable
shields should be terminated on the ACS 6000 side only. Either single or
multiple twisted pair cables may be used.
Table 9-3 Control Cable Requirements
Cross-Section
Signal Type General Cable Type
(I/O Termination)
Analog In 0.5 to 2.5 mm2 /

Twisted pair(s) - Overall Shield
AWG 20 to AWG 12
Analog Out 0.5 to 2.5 mm2 /

Twisted pair(s) - Overall Shield
AWG 20 to AWG 12
Digital In 0.5 to 2.5 mm2 /

Twisted pair(s)
AWG 20 to AWG 12
Digital Out 0.5 to 2.5 mm2 /

Twisted pair(s)
AWG 20 to AWG 12
Speed Encoder Twisted pair cable with a common 0.5 mm2

shield and separate pair shields 4 x (2+1)
Position Encoder Twisted pair cable with a common 0.5 mm2

shield and separate pair shields 14 x (2+1

Synchronization Synchronization cables are not applicable for ACS 6000 with line supply
Cables unit. A 3-phase shielded cable without neutral wire is required for the
voltage supply of the synchronization transformer. For information on
ratings contact ABB.

Chapter 10 - Installation Guidelines
10.1 Space Requirements
The length of the ACS 6000 depends on the configuration (number and
type of modules). The height (2200 mm) and depth (1000 mm) are the
same for all configurations.
ABB recommends a minimum free space of 400 mm behind and on both
sides of the converter for installation, service and repair purposes as well
as for cooling purposes (see Figure 10-1).
The free space above must not be less than 700 mm for installation,
cooling and explosion protection purposes.
A minimum free space of about 1500 mm has to be guaranteed in front of
the converter as an escape route. However, this distance might vary
according to local regulations.
The dimensions below do not include space for cable and water entries
(top and bottom entries possible). Dimensions must be specified when
ordering the ACS 6000.
Min.
700
TEU
ARU INU CBU VLU WCU EXU
COU
2200
Recommended 400 mm or more

Min.
400
Min. Min.
400 400
1000
500
500
600
750
750
800
800
Min.
800
Figure 10-1 Space Requirements (Dimensions in mm)

The lengths of typical drive configurations are given in Appendix A - Tech-

nical Data.
Transportation Units The base frame for the transportation units is part of the scope of supply.
The maximum length of the base frame is 6.4 m. The length of the trans-
portation units will be suggested in the quotation.
The converter can also be shipped devided into individual modules
(without base frame) if the space for installation is limited. The final
converter alignment remains unchanged.
10.2 Structural Requirements
Foundation and Floor Cabinets must be installed in upright position.

Levelling
The floor must be of non-flammable material, with a smooth and non abra-
sive surface, protected against humidity diffusion, levelled and able to
support the weight of the converter (min. 1’000 kg/m2).
Cable Trays and Holes Cable trays must be of non-flammable material with non abrasive surface.
Holes in the floor or in the wall(s) have to be prepared for planned cable
and cooling water pipe penetrations (according to the final layout draw-
ings).
A protection against fire spreading, humidity, dust and penetration by
animals must be forseen.
Ventilation A part ot the heat losses are dissipated to the air even if the converter is
water-cooled. For this reason the installation site must be ventilated in
order to fulfill the requirements to ambient conditions specified in Appendix
A - Technical Data, Environmental Aspects, page 157. The heat losses to
air depend on the converter configuration.
Safety Aspects For safety reasons sufficient illumination of the electrical room has to be
forseen (typically 100 lux with white fluorescent lamps).
Local safety regulations must always be considered (e.g. door locks for
electrical room).
10.3 Mechanical Installation
The converter must always be lifted either by crane or by fork using ropes
and the supplied lifting rings. These rings are screwed into the base frame.
The lifting ropes should be at an angle as indicated in Figure 10-2.

Cable angle
MAX. indicated on
30° cabinet roof
120°
Cabinet with Base Frame Cabinet without Base Frame
Figure 10-2 Rope Angle for Cabinet Lifting
10.4 Power Cable Installation, Grounding and Shielding
This chapter describes the minimal requirements for power cable installa-
tion, grounding and shielding. Additional requirements in local regulations
have to be considered.

10.4.1 Connecting ARU to Supply Transformer

Figure 10-3 shows an installation with 3 cables running in parallel. The
total cable diameter is defined by the power consumption of the drive.
Feeding transformer
Ground Feeding transformer
cable or busbar
or busbar
PE L1 L2 L3 PE
L1 L2 L3 PE
1 2 3 1 2 3 1 2 3
A > 16 mm2 Armor

(Cu)
Shield
1 2 3 1 2 3 1 2 3
1L1 1L2 1L3 PG PE PE PG 1L1 1L2 1L3

PG
TEU TEU
ACS 6000 ARU ACS 6000 ARU
~ = ~ =
a) with 3 core cables b) with single core cables
Figure 10-3 ARU Side Cabling

10.4.2 Connecting LSU to Supply Transformer
Feeding transformer
U1 V1 W1 U2 V2 W2 PE
1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3
Shield
Armor
16 mm2 < A
1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3
(Cu)
1L1 1L2 1L3 2L1 2L2 2L3 PG PE
TEU
ACS 6000 LSU
~ =
Figure 10-4 LSU Side Cabling

10.4.3 Connecting Motor to INU
ACS 6000 INU ACS 6000 INU

Ground
cable
PG
=
TEU
~ =
TEU
~
L1 L2 L3 PG PE PE PG L1 L2 L3
1 2 3 1 2 3 1 2 3
Armor
Shield
A > 16 mm2
(Cu)
1 2 3 1 2 3 1 2 3
PE U1 W1 U1 V1 W1
V1
PE PE
Motor Motor
a) with 3 core cables b) with single core cables
Figure 10-5 INU Side Cabling

10.4.4 Equipment Grounding

A safety ground busbar (protective earth, PE) is installed through all
converter cabinets (in the bottom area of the cabinets). At one point (inside
the terminal unit which is closest to the capacitor bank unit) it must be
connected to system grounding. Connection to system ground has to be
established in compliance with local regulations.
L3 L2 L1
1L3
1L2
1L1
Safety Ground (PE)

to be connected to
2L1 system ground
2L2
2L3
Figure 10-6 TEU, Connection to System Ground


Appendix A -Technical Data
Converter Output / Motor Connection
The converter types listed in the table below correspond to a part of the
type code as explained in Appendix C - ACS 6000 Type Code.
The most important characters are:
• "x" stands for S (single-motor drive), M (multi-motor drive), R (redun-
dant drive) and T (twin drive)
• "..." stands for several digits of the type code (see Appendix C - ACS
6000 Type Code)
• "y" stands for asynchronous motors, synchronous motors and syn-
chronous motors with brushless excitation.
Table A-1 Output Voltage and Current Ratings
Rated Output Voltage with Rated Output Voltage

Rated Output Rated Output
Type LSU with 2 x 1725 V Input with LSU with 2 x 1650 V
Voltage with ARU Current
Voltage Input Voltage
ACx ... _1y7 3150 ... 3300 V 3000 ... 3100 V 3000 V 1300 A
ACx ... _1y9 3150 ... 3300 V 3000 ... 3100 V 3000 V 1670 A
ACx ... _2y7 2 x 3150 ... 3300 V 2 x 3000 ... 3100 V 2 x 3000 V 2 x 1300 A
ACx ... _2y9 2 x 3150 ... 3300 V 2 x 3000 ... 3100 V 2 x 3000 V 2 x 1670 A
Output Frequency 0...75 Hz

Range
Minimal Base 6.25 Hz

Frequency
Maximum Field 1:5

Weakening Range
Maximum Motor Cable 300 m (984 ft)

Length
Efficiency Depending on individual configuration.
Static Speed With encoder: within +/- 0.01%

Inaccuracy
Without encoder: within +/- 0.1%
Dynamic Speed With encoder: within 0.2 ... 0.5% s

Inaccuracy
Without encoder: within 0.5 ... 1% s

Appendix A - Technical Data
Air Gap Torque Ripple < 1% (Motor fn <25 Hz, frequency components below 100 Hz)
Components
< 2% (Motor fn <50 Hz, frequency components below 100 Hz)
< 3% (Motor fn <60 Hz, frequency components below 100 Hz)
Power Factor For synchronous motors controlled to 1.0

For asynchronous motors depending on motor characteristics.
ARU Input
Table A-2 Input Voltage and Current Ratings
Reinforced EMC
Type Input Voltage Rated Input Current Pulses
Filter (IFU)
ACx 6107_A06_... 1 x 3160 V, +10/-10% 1 x 1300 A 6-pulse No
1 x 3000 V, +15/-5% 1 x 1300 A 6-pulse No
1 x 3000 V, +15/-5% 1 x 1670 A 6-pulse No
ACx 6109_F06_... 1 x 3160 V, +10/-10% 1 x 1300 A 6-pulse Yes
1 x 3000 V, +15/-5% 1 x 1300 A 6-pulse Yes
2 x 3000 V, +15/-5% 2 x 1380 A 12-pulse No
2 x 3000 V, +15/-5% 2 x 1670 A 12-pulse No
3 x 3000 V, +15/-5% 3 x 1670 A 18-pulse No
Input Voltage Safe operation with reduced output power is possible down to -20% for
Variations 3160 V input voltage.
Phase Shift Phase shift between transformer secondary windings:

• 30° for 12-pulse ARUs
• 20° for 18-pulse ARUs
Input Frequencies 50 / 60 Hz ± 5%
Voltage Unbalance max. ± 2% (Uneg / Upos according to IEC 61000-2-4)

Fundamental Power Controlled to cos ϕ = 1.0

Factor
Optionally cos ϕ can be controlled in a range of 0.8 (lead) ... 0.8 (lag).
(MVA ratings remain the same as for cos ϕ = 1.0)
Maximum Cable 300 m (984 ft)

Length
Control Principle Vector Control with optimized pulse patterns
LSU Input
Table A-3 Input Voltage and Current Ratings
Type Input Voltage Rated Input Current Pulses
ACx 6107_L12_... 1 x 2 x 1725 VAC, +10/-10% 1 x 2 x 1300 A 12-pulse
1 x 2 x 1650 VAC, +15/-5% 1 x 2 x 1300 A 12-pulse
1 x 2 x 1650 VAC, +15/-5% 1 x 2 x 1670 A 12-pulse
1 x 2 x 1650 VAC, +15/-5% 1 x 2 x 2600 A 12-pulse
2 x 2 x 1650 VAC, +15/-5% 2 x 2 x 1300 A 24-pulse
2 x 2 x 1650 VAC, +15/-5% 2 x 2 x 1670 A 24-pulse
2 x 2 x 1650 VAC, +15/-5% 2 x 2 x 2600 A 24-pulse
Phase Shift Phase shift between transformer secondary windings:

• 30° for 12-pulse LSUs
• 15° for 24-pulse LSUs
Input Frequencies 50 / 60 Hz ± 2%
Voltage Unbalance max. ± 2% (Uneg / Upos according to IEC 61000-2-4)
Fundamental Power cos ϕ > 0.95

Factor
Maximum Cable 300 m (984 ft)

Length

Auxiliary Supply
Auxiliary Voltage • 380 VAC +/-10%, 3 phase

• 400 VAC +/-10%, 3 phase
• 415 VAC +/-10%, 3 phase
• 440 VAC +/-10%, 3 phase
• 460 VAC +/-10%, 3 phase
• 480 VAC +/-10%, 3 phase
• 500 VAC +/-10%, 3 phase
• 660 VAC +/-10%, 3 phase
• 690 VAC +/-10%, 3 phase
Auxiliary Voltage 50 / 60 Hz, +/-2%

Frequency
Uninterruptible Power 110 VDC

Supply
220 VDC
110 VAC, 1 phase
230 VAC, 1 phase
EXU Supply
Auxiliary Voltage • 380 VAC +/-10%, 3 phase

• 400 VAC +/-10%, 3 phase
• 415 VAC +/-10%, 3 phase
• 440 VAC +/-10%, 3 phase
• 460 VAC +/-10%, 3 phase
• 480 VAC +/-10%, 3 phase
• 500 VAC +/-10%, 3 phase
• 660 VAC +/-10%, 3 phase
• 690 VAC +/-10%, 3 phase
Auxiliary Voltage 50 / 60 Hz, +/-2%

Frequency

Environmental Aspects
Ambient Temperature The permitted temperature range for the ACS 6000 is:
• +5…+40 °C (41…104 °F)
• +5…+45 °C (41…113 °F) for marine types
Environmental The environmental parameters describing the climatic and mechanical

Parameters conditions are based on the classification of the environmental conditions
according to IEC 721-3 standard series.
• IEC 721-3-3 Stationary use at weatherprotected locations (operation)
The environmental class for operation is a combination of IEC 721-3-3
classes 3K3/3B1/3S2/3M3.
Installation Site Altitude • 0 ... 2000 m (standard range)

• up to 5000 m with derating
Relative Humidity The permitted range for relative humidity is: 5…95%; no condensation is
allowed
Sound Pressure Level < 75 dB (A)
Derating of Drive Power
Derating for Raw Water If the raw water temperature exceeds 32 °C (90 °F) the output current will
Temperature be derated by 1.5%/°C. The maximum raw water temperature is 42 °C
(108 °F).
Low Speed Operation Continuous current derated to 70% / 0 Hz ... 70% / 3 Hz ... 100% / 8 Hz
Transportation and Storage
Temperature • IEC 721-3-1 Storage

• IEC 721-3-2 Transportation
The environmental class for storage is a combination of IEC 721-3-1
classes 1K4/1Z3/1B1/1M3 temporary condensation is allowed.
The environmental class for transportation is a combination of IEC 721-3-
2 classes 2K4/2B1/2M1 but low air pressure can be 60 kPa.

Cooling
Cooling Method Water-cooled closed loop system.
Heat Dissipation to Approx. 6% of losses

Environment
Raw Water +10 … +36 °C (50 ... 97 °F)

Temperature for Marine
Raw Water Pressure < 10 bar (< 144.2 lb/sq in)
Extended Raw Water +32 … +42 °C (90 ... 108 °F)

Temperature
Main Cooling Circuit After the installation of the modules, the cooling circuit has to be filled with
deionized water.
The required quantity of deionized water for an ACS 6000 varies,
depending on the configuration.
Make-up Water Drinking water of good quality generally meets the requirements for make-
up water and may be used. Conditioning make-up water will result in an
initial reduction of the deionizer resin capacity by about 10%. The basic
quality parameters for make-up water are given in Table A-4. If there is any
doubt about the quality of drinking water, contact your water utility or your
local ABB representative.
Table A-4 Make-up Water Quality Requirements
Parameter Value
pH 7 – 8.5
specific conductivity < 300 µS/cm
hardness 3 – 10° dH
chloride (Cl) < 300 mg/l
copper (Cu) < 0.1 mg/l
total dissolved salt < 1000 mg/l
undissolved particles < 5 mg/l
Raw Water Circuit Raw water of good quality is essentially “industrial water”. Requirements
to the quality of raw water are given in Table A-5. If there is any doubt
about the quality of drinking water, contact your water utility or your local
ABB representative.

Table A-5 Industrial Water Quality Requirements
Parameter Value
pH 7–9
specific conductivity < 500 µS/cm
hardness 3 – 15° dH
chloride (Cl) < 300 mg/l
total dissolved salt < 1000 mg/l
undissolved particles < 1000 mg/l
Total M-alkalinity (TAC) 0 - 300 mg CaCO3/l
Customer Interface The raw water supply is connected to the cooling circuit with two flanges
which are part of the supply. Raw water pipes can be connected to the
converter through top or bottom of the WCU cabinet. Requirements for the
raw water connection are given in Table A-6.
Table A-6 Requirements for Raw Water Connection
Raw water circuit specification ACS 6000 Remarks
Flow Rate 250 - 870 l/min* Depending on the size of ACS 6000
Pressure Drop Depending on size of ACS 6000 and

70 - 160 KPa*
application
Design Pressure 1000 KPa*
Test Pressure 1500 KPa*
Inlet Temperature 10 - 32 °C* (50 ... 90 °F)

Inlet Temperature (Marine version) 10 - 36 °C* (50 ... 97 °F)
Extended Temperature 32 - 42 °C* (90 ... 108 °F)
Outlet Temperature 10 - 37 °C* (50 ... 99 °F)
* Nominal values; values vary depending on application.
Converter Enclosure
Standard Enclosure IP32

Class
Cabinet Color RAL 7035 "Light Gray"

Language
Documentation The standard language of the ACS 6000 User’s Manual is English.
Warning Labels The standard language of the ACS 6000 warning labels is English.

Appendix B - Applicable Codes and Standards
General
The most important standards for design, construction and test proce-
dures of ABB converters are listed in this document.
International Standards for Design and Construction
• DIN/EN 60146 / IEC 60146: 1991

Semiconductor converters; General requirements and line commu-
tated Converters
• IEC 664-1: 1992
Insulation coordination for equipment within low-voltage systems
• EN 50178: 1996
Electronic equipment for use in power installations
• DIN/EN 60204-1
Safety of machinery - Electrical equipment of machines;
Part 1: General requirements
• IEC 721-3-1 A1: 1991
Classification of environmental conditions
Part 3: Storage
• IEC 721-3-2 A2: 1993
Classification of environmental conditions
Part 3: Transportation
• IEC 721-3-3 A1: 1995
Classification of environmental conditions;
Part 3: Stationary use at weatherprotected locations
• EN 292: 1991
Safety of machinery: Basic concepts, general principles for design
• IEC 22B/88/CD: 1995-06
Draft revision of IEC 146-2: Self-commutated convertors including
direct DC convertors and IEC 146-3: Semiconductors direct DC
convertors DC chopper convertors.
• IEC 529: 1989
Degrees for protection provided by enclosures (IP-Code)

• IEC 664
Semiconductor converters
• EN 50178
Insulation coordination
• EN 50178
Safety
• EN 61800
Test requirements
• IEC 529
Degrees of protection provided by enclosures
• IEEE 444
Practices and requirements for thyristor converter motor drives
EMC Standards
• EN 61000-4-2
Electrostatic discharge (ESD)
• contact discharge 4 kV
• air discharge 8 kV
• EN 61000-4-3
Radiated electromagnetic field immunity (RFI)
• EN 61000-4-4
Electrical fast transient (Burst)
• Aux-Supply Power-Ports: 2 kV, 5 kHz
• Signal-Ports: 2 kV, 5 kHz
• EN 61000-4-5
Surge immunity
• EN 61000-4-6
Conducted interference immunity
• EN 55011 A
Suppression of Radio disturbances caused by electrical appliances
and systems
• Aux Supply Power Ports conducted emission
0.15 - 30 MHz Class A
• CISPR 11
Class A equipment for emission

• IEEE 519
Recommended Practices and Requirements for Harmonic Control in
Electrical Power Systems
• EN 50178: 1996
Electronic equipment for use in power installations; Final Draft
Marine Standards for ACS 6000 Marine Drives
• IEC 68-2-6
Vibration (Damping)
• IEC 68-2-2
Dry heat
• IEC 68-2-1
Cold
• IEC 68-2-30
Humidity
• IEC 68-2-52
Salt mist
• IEC 60092
Installation in ships
• IEC 721-3-6
Ship environment


166
Appendix C - ACS 6000 Type Code

1 2
AC drive AC = AC drive A C
Configuration S = Single motor drive
M = Multi motor drive
R = Redundant drive (2 WCU, 2 EXU, 2 CBU , final scope of a redundant drive is not fixed) 3 4
T = Twin configuration
5
ACS 6000 family 6 = 6000 family 6

Amount of supply units 1 = 1 supply unit
2 = 2 supply units
3 = 3 supply units (only with ARU) 6
4 = 4 supply units (only with LSU)

Power of each supply unit 07 = 7 MVA
09 = 9 MVA 7 8 9
14 = 14 MVA (only with LSU) _
Type of input section A = Active Rectifier Unit (ARU)

L = Line Supply Unit (LSU)
F = Active Rectifer Unit with input filter (6 pulse) 10
D = Direct on line (max 7MVA wit IRU, Input filter unit)

Number of pulses 06 = 6 pulse input circuit
12 = 12 pulse input circuit
18 = 18 pulse input circuit (only with ARU) 11 12 13
24 = 24 pulse input circuit (only with LSU) _
Machine 1 1 = 1 inverter 14
2 = 2 inverters
s = synchronous machine, excited by sliprings or brushless
a = asynchronous machine 15
p = permanent magnet machine (future option)

5 = 5 MVA inverter(s)
7 = 7 MVA inverter(s) 16 17
9 = 9 MVA inverter (s) _

18 19 20 21
Machine 2 (optional) same possibilities as machine 1 _

22 23 24 25

26 27 28 29

30 31 32 33
Machine 5 (optional) same possibilities as machine 1 (only with LSU) _
VLU, RBU or BCU 1 or 2 = Number of Units (position 34)

(optional) V1 = Voltage Limiter Unit (VLU), 480kJ (use with single ARU)
V2 = Voltage Limiter Unit (VLU), 960kJ (use with double ARU)
V3 = Voltage Limiter Unit (VLU), 1450kJ (use with triple ARU)
B1 = Braking Chopper Unit (BCU) 34 35 36 37
R1 = Resistor Breaking Unit (RBU), 10MJ _

R2 = Resistor Breaking Unit (RBU), 20MJ
= if none selected, DIU will be automatically added to first CBU
38 39 40
CBU C2 = Capacitor Bank Unit (CBU) with 2 rows of capacitors (9 MVA) _

41 42 43
CBU (optional) same possibilities as CBU _
WCU W1 029SG 137kW 44 45 46
W2 052SG 270kW _
W3 080SO 350kW
W4 106SO 390kW
W5 120SO 400kW
47 48 49
future options _
Customer interface in WCU CIW1 = TB 820 + 5 predefined I/O modules connected to AMC3 in WCU swingframe (only for single machine drives)
(optional) CIW2 = 1 (or 2) AC80 + I/O modules (total 6 modules) in WCU swingframe. AC80 SW not included. 50 51 52 53 54
CIW3 = 1 (or 2) AC80 + I/O modules (total 6 modules) in WCU swingframe. AC80 SW included. _
55 56
Customer interface in 1 ... 5 = Number of CIWx I/O sets (one set per machine) _
separate cabinet CIU1 = TB 820 + 5 I/O modules (as CIW1) per machine installed in one separate cubicle. CTRL with AMC3 SW.
(optional) CIU2 = AC 80 + I/O sets per machine installed in one separate cubicle. AC80 SW not included. 57 58 59 60 61
CIU3 = AC 80 + I/O sets per machine installed in one separate cubicle. AC80 SW included. _
Engineered extension CIU = Empty control cabinet, integrated to line-up 62 63 64 65
(optional) CIUe = Project specific engineered I/O solution (separate cubicle(s))

Appendix C - ACS 6000 Type Code
Type Code Limitations

• Number of ARU + number of INU < or = 6
• Use DIU, if there is no VLU, RBU of BCU
• Order of alignment is pre-defined
• Size of WCU: defined by sum of rated water flows of all modules
• Size(s) of CBU: defined by sum of ARU + INU rated power * 0.5 mF/
MW
• Max. number of ARU / INU left of CBU: 3
• Max. number of ARU / INU right of CBU: 3
• If IFU: ARU9 = 7 MVA continuous

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What are the different types of ACS 6000 drive configurations?

What are the different types of ACS 6000 drive configurations?

What are some examples of applications for the ACS 6000 drives?

What are some examples of applications for the ACS 6000 drives?

ACS 6000

Medium Voltage Drives

Document No.: 3BHS132322 ZAB E01, Rev. B

Effective: February 2003

 ABB Switzerland Ltd. All Rights Reserved.

ACS 6000 Technical Catalog

Chapter 2 - Types and Applications 21

Chapter 3 - Key Technologies 37

ACS 6000 Technical Catalog 1 / 166

Chapter 5 - Description of Modules 57

2 / 166 ACS 6000 Technical Catalog

ACS 6000 Technical Catalog 3 / 166

6.1 Control Hardware Concept 87

Chapter 7 - Standard Control and Protection Functions 115

7.1 General 115

4 / 166 ACS 6000 Technical Catalog

Chapter 8 - Options 125

8.1 Converter Hardware 125

Chapter 9 - Requirements for System Components 131

9.1 General 131

ACS 6000 Technical Catalog 5 / 166

Chapter 10 - Installation Guidelines 145

10.1 Space Requirements 145

Appendix A - Technical Data 153

Converter Output / Motor Connection 153

6 / 166 ACS 6000 Technical Catalog

Appendix C - ACS 6000 Type Code 165

Type Code Limitations 166

ACS 6000 Technical Catalog 7 / 166

AC80 Advant Controller

AF100 Advant Fieldbus 100 (ABB Bus System)

AMC Application and Motor Controller

AMCOS Application and Motor Controller Operating System

ARU Active Rectifier Unit

ASE Anti Saturation Equipment

BCU Braking Chopper Unit

BOD Breakover Diode

CBU Capacitor Bank Unit

CCB Converter Controller Board

CDP 312 Control Panel

CHU Charging Unit

CIU Customer Interface Unit

CIW Customer Interface Unit (integrated into WCU)

COU Control Unit

CVMI Current and Voltage Measuring Interface Board

CWU Control Water Unit (control equipment inside WCU)

DC_NP DC Neutral Point

DDCS Distributed Drive Control System (communication

DIU Discharging Unit

DTC Direct Torque Control

ECB Excitation Circuit Breaker

EMC Electromagnetic Compatibility

ACS 6000 Technical Catalog 9 / 166

FCB Function Chart Builder

FCI Fieldbus Communication Interface