G740 Inverter Unit Rev

ABB ACS 5000 Training
ACS 5000 Service & ACS 5000

Commissioning
Inverter Unit
Course G740
ACS 5000 Training –RevB2
© ABB Ltd - 1 -
© ABB Ltd Page 1

Inverter
Training objectives
Upon completion of this part the student will be able to

handle the hardware including:
n Main circuit diagram
n Operating principle (5-level topology)
n Function of components and printed circuit boards
n Control HW
© ABB Ltd - 2 -
© ABB Ltd Page 2

Inverter
ACS 5000 Main circuit diagram
transformer motor
MCB
© ABB Ltd - 3 -
§ Three splitted dc-links

§ Each dc-link is delivering the power for one
motor phase
© ABB Ltd Page 3

Inverter
ACS 5000 Inverter Unit
(=INU)
Inverter Unit 12 MVA, 6.9 kV (single INU)

18 MVA, 6.9 kV (double INU)

© ABB Ltd - 4 -
24 MVA, 6.9 kV (double INU)
§ Voltage Source Inverter Multilevel-Fuseless (VSI-MF)

§ 9 levels line-to-line
§ Rated output voltage: 6.0-6.9kV
§ Optional: 4.16kV
© ABB Ltd Page 4

Inverter
Inverter Unit main components
Interface board
Phase module W
(=INU 3)
Hard coupled Phase module V

capacitors (=INU 2)
Phase module U
(=INU 1)
© ABB Ltd - 5 -
The main components of the Inverter Unit are :
§ 3 Phase modules called PEBB (Power Electronic Building

Block)
§ 9 IPSs (Igct Power Supply) (3 per phase) to supply Gate
Units and printed circuit boards.
§ 3 Interface boards
§ 3 CVMI boards (Current and Voltage measurement)
© ABB Ltd Page 5

Inverter
© ABB Ltd - 6 -
Main circuit diagram
© ABB Ltd Page 6

Inverter
Phase module main diagram
n Inverter unit of one phase
n One three-level inverter to the motor
n One three-level inverter to a common rail (star point) of all
phases
© ABB Ltd - 7 -
The main components of the phase module are :

§ 8 RC-IGCTs (Reverse Conducting Integrated Gate
Commutated Thyristor). Integrated freewheeling diodes
parallel to IGCTs,
§ 4 Neutral point diodes divide DC voltage equally across
RC-IGCTs and protects the components when the RC-
IGCTs
of the other leg are turned off. Neutral point diodes are also
an
important part of 5-level topology.
§ 4 clamping diodes
§ 4 clamping capacitors
© ABB Ltd Page 7

Inverter
How to reach the 6.9 kV: principle
n Creating one line to line motor voltage
DC+
NP
DC-
common motor line to
rail DC+ line voltage
NP
DC-
© ABB Ltd - 8 -
MOTOR
© ABB Ltd Page 8

Inverter
© ABB Ltd - 9 -
Current flow according to princible above:

VLSCD
7u
DC + H
2.5
2.5
DC (NP)
12k
12k
DC (NP)
2.5
2.5
7u
DC - H
A2 A1
VLSCD common
VLSCD
7u
DC + H MOTOR
2.5
2.5
DC (NP)
12k
12k
DC (NP)
2.5
2.5
7u
DC - H
VLSCD common
© ABB Ltd Page 9

Inverter
© ABB Ltd - 10 -

VLSCD
7u
DC + H
2.5
2.5
DC (NP)
12k
12k
DC (NP)
2.5
2.5
7u
DC - H
A2 A1
VLSCD common
VLSCD
7u
DC + H MOTOR
2.5
2.5
DC (NP)
12k
12k
DC (NP)
2.5
2.5
7u
DC - H
VLSCD common
© ABB Ltd Page 10

Inverter
© ABB Ltd - 11 -

VLSCD
7u
DC + H
2.5
2.5
DC (NP)
12k
12k
DC (NP)
2.5
2.5
7u
DC - H
A2 A1
VLSCD common
VLSCD
7u
DC + H MOTOR
2.5
2.5
DC (NP)
12k
12k
DC (NP)
2.5
2.5
7u
DC - H
VLSCD common
© ABB Ltd Page 11

Inverter
© ABB Ltd - 12 -

VLSCD
7u
DC + H
2.5
2.5
DC (NP)
12k
12k
DC (NP)
2.5
2.5
7u
DC - H
A2 A1
VLSCD common
VLSCD
7u
DC + H MOTOR
2.5
2.5
DC (NP)
12k
12k
DC (NP)
2.5
2.5
7u
DC - H
VLSCD common
© ABB Ltd Page 12

Inverter
© ABB Ltd - 13 -

VLSCD
7u
DC + H
2.5
2.5
DC (NP)
12k
12k
DC (NP)
2.5
2.5
7u
DC - H
A2 A1
VLSCD common
VLSCD
7u
DC + H MOTOR
2.5
2.5
DC (NP)
12k
12k
DC (NP)
2.5
2.5
7u
DC - H
VLSCD common
© ABB Ltd Page 13

Inverter
n The line to line voltage at basic switching

motor line to line voltage
10000 V
5000 V
time
-5000 V
-10000 V
© ABB Ltd - 14 -
© ABB Ltd Page 14

Inverter
© ABB Ltd - 15 -
© ABB Ltd Page 15

Inverter
© ABB Ltd - 16 -
© ABB Ltd Page 16

Inverter
Hard coupled DC-Link
§ Hard coupled:
Directly connected to the DC
busbars
© ABB Ltd - 17 -
© ABB Ltd Page 17

Inverter
Di/Dt limiting chokes
§ Chokes protect diodes and IGCTs from excessive di/dt.

© ABB Ltd - 18 -
§ Two chokes (LCL1, LCL2) are included to limit the current rate of
rise in negative and positive DC busses
§ They are needed to protect diodes and IGCTs from excessive
di/dt.
§ In case of short circuit or firing through (protection function of the
drive) di/dt chokes must be able to limit and withstand huge
currents
and current rate of rise.
§ VLSCD (Voltage Level Short Circuit Detection) board is connected
in
parallel to each DC choke. They are used to detect a short circuit
and IGCT malfunction.
© ABB Ltd Page 18

Inverter
Inverter phase module
§ Inverter phase module
Weight: ~200 kg
1 phase H-bridge
© ABB Ltd - 19 -
© ABB Ltd Page 19

Inverter
Phase module
Phase module
VLSCD
A1 A2
7uH
Clamping Dcl Dcl
Diode 2.5
V21 V11
RC-IGCT
2.5
Dnp Dnp
2uF 2uF
V22 V12
DC (NP)
12k
12k
DC (NP)
2uF 2uF
V23 V13
Dnp Dnp
2.5
Clamping 2.5
V24 V14
Capacitor Dcl Dcl
7uH
A2 A1
VLSCD
common
H-brigde with clamping circuit

© ABB Ltd - 20 -
NP-Diode
The main components of the phase module are :

§ 8 RC-IGCTs (Reverse Conducting Integrated Gate
Commutated Thyristor). Integrated freewheeling diodes
parallel to IGCTs,
§ 4 Neutral point diodes divide DC voltage equally across
RC-IGCTs and protects the components when the RC-
IGCTs
of the other leg are turned off. Neutral point diodes are also
an
important part of 5-level topology.
§ 4 clamping diodes
§ 4 clamping capacitors
© ABB Ltd Page 20

Inverter
Clamping Circuit
§ Clamping Circuit prevents excessive voltages formed over the
components when an IGCT turns off.
Clamping
Diode
Clamping
Capacitors
© ABB Ltd - 21 -
§ Circuit formed by diode (Dcl1, Dcl2), resistor (Rcl1, Rcl2) and

capacitor (Ccl1, Ccl2) discharges the energy stored in the di/dt
choke and inverter diodes and IGCst
© ABB Ltd Page 21

Inverter
Neutral Point Diodes
§ Neutral point diodes divide DC voltage equally across IGCTs
and protects the components when the IGCTs of the other leg
are turned off.
Neutral Point
Diode
© ABB Ltd - 22 -
© ABB Ltd Page 22

Inverter
Balancing resistors
§ Balancing resistors provides voltage sharing when all IGCTs are
turned off and it prevents unbalance between half DC link voltages.
© ABB Ltd - 23 -
© ABB Ltd Page 23

Inverter
Integrated Gate Commutated Thyristor
§ INU IGCTs free wheeling diode is integrated with IGCT
RC-IGCT
© ABB Ltd - 24 -
RC-IGCT (used in ACS 5000)
Integrated Gate Commutated Thyristor + Integrated freewheeling diode
IGCT + Freewheeling diode
Integrated Gate Commutated Thyristor + separate Freewheeling diode
© ABB Ltd Page 24

Inverter
Charging
7uH
Dcl Dcl
V21 V11
2.5
6x 2.5
1.3mF
2uF Dnp 2uF Dnp
V22 V12
ph_mot
12k
12k
DC (NP) DC (NP)
2uF 2uF
V23 V13
Dnp Dnp
6x
1.3mF
2.5
2.5
V24 V14
Dcl Dcl
7uH
DC link HV Relay
common
© ABB Ltd - 25 -
Aux
Charging Circuit
§ Connecting the charging transformer between DC-link neutral point

and the common-rail, the reverse conducting diodes of the INU
IGCTs act as charging rectifier.
§ Because of the connection to the common rail, the drive needs
only
one 3-phase transformer for charging all tree circuits circuit.
NP phase 3 NP phase 2 NP phase 1

common rail
HV-relay
© ABB Ltd Page 25

Inverter
Charging sequence
MAX
DC bus charging sequence = 20 s
5400VDC
Values
5000VDC
DC VOLTAGE
MCB order close

MIN
© ABB Ltd - 26 -
Times (s)
Charging sequence:
§ At the beginning Main Circuit Breaker (MCB) is off

(Drive status: RDY ON)
§ Precharging the DC-link (capacitors) is done by using charging circuit

(Charging transformer). The capacitors are charged before the
converter
is connected to the main power source to avoid excessive inrush
currents. (Drive status: Charging)
§ The voltage of the dc-link will rise to a defined limit (“DC charging
level”:
5000V). At this limit the HV-relay will be opened.
§ “MCB closing level” (should be at least 100V less than value “DC
charging level” ). =>MCB closing is enabled.
§ MCB is on and dc-voltage reach it’s nominal level.
© ABB Ltd Page 26

Inverter
INU Control HW
VLSCD
Phase Modules
DC +
Phase
NP NP
DC -
VLSCD
common
IPS
IPS
IPS
HVD
CVMI
© ABB Ltd - 27 -
INT board PEC-INT Main
§ INTerface board generates the firing pulses to the IGCTs

according
to the AMC-board instructions. Also, INT board centralizes all
measurements (current and voltage) and by this way, includes fast
software protections.
§ Current and Voltage Measurement Interface converts DC voltage

and phase currents measurements to numeric values. CVMI also
includes inverter overcurrent hardware detection.
§ High Voltage Divider board measures the DC voltages and

transfers
the results to CVMI.
§ Two Voltage Level Short Circuit Detection boards allow INTerface

board to detect IGCT fault and short circuit.
§ Three IGCT Power Supply units feed aux. Power to all IGCTs
and some printed circuit boards via voltage sub print.
© ABB Ltd Page 27

Inverter
Interface Board (INT)
§ Interface Board and CVMI board

are installed in drawer
© ABB Ltd - 28 -
INTerface description:
§ INT-board is an interface between AMC-33 and all other printed
circuit boards
§ INT-board includes fast SW protections like overcurrent detection
(from CVMI) or IGCT fault detection (from IPS or FSCD).
© ABB Ltd Page 28

Inverter
§ Interface board (INT) serving as a
communication interface to the control
system in the COU.
§ The pulse firing logic for the IGCTs and fast
protection functions are integrated on the
board as well.
§ Fiber optic cables are used for transmission
of data between the interface board and the
control system and for the gate firing signals
of the IGCTs.
© ABB Ltd - 29 -
© ABB Ltd Page 29

Inverter
Interface Board (INT) / EPLD SW
PLD circuit #1 PLD circuit #0
Control SW EPLD:
§ Modulator
§ HW protections
§ EPLD Registers
§ BCU Control
§ PPCS Communication Interface
IMPORTANT !!! EPLD SW

version must be compatible with
© ABB Ltd - 30 -
the type of the unit and with other

SWs in ACS 5000 (INT Flash,
AMC Flash, CCB SW etc.)
Note! these two circuits have different firmware in them. They are
identified with numbers #0 and #1 on the label
© ABB Ltd Page 30

Inverter
LSU Discharging Unit Power
or Supply
Optional Braking Chopper
X8
Phase module
(8 RC-IGCT’s)
X2
FT Link
VLSCD, fast short

circuit detection
PEC-INT Board
in COU
© ABB Ltd - 31 -
IPS, IGCT Power Supply CVMI,current and voltage measurement
© ABB Ltd Page 31

Inverter
VLSCD_P2_LSU
IOC from CVMI
IOV from CVMI
RC-IGCT firing PWF_IPS1

PWF_IPS2
INU 1_3 PWF_IPS1 (double INU)
PWF_IPS2 (double INU)
VLSCD_P1
VLSCD_N1
RC-IGCT firing VLSCD_P1_LSU
VLSCD_N1_LSU
double INU VLSCD_P2 (double INU)
VLSCD_N2 (double INU)
VLSCD_N2_LSU
DIU or optional
Braking chopper CVMI Communication
RC-IGCT firing
double INU PEC-INT Communication
© ABB Ltd - 32 -
FT-link
Aux power supply
§ The board has 26 plastical optical transmitters and 21 receivers.

All
communication is made by fibre optics.
§ 24V-power supply
© ABB Ltd Page 32

Inverter
§ INT board diagnostics: Indication LEDs
2 greens LEDs (V103, V113)

for „POWER O.K.“. If they
are on, the internal +5V DC
supply voltages are
within the allowed limits.
8 yellow LEDs (V561…V568) for testing the 1 yellow LED „CONFIG. FAULT“
near the EPLD circuit. LED is on
Firmware in EPLD (Firmware specific)
during EPLD configuration
© ABB Ltd - 33 -
© ABB Ltd Page 33

Inverter
High Voltage Divider (HVD) board
§ This board takes care of the voltage division from high voltage
down to the low voltage input range of the CVMI.
§ This board is equipped with passive components only and does
not require a supply voltage.
DC +
DC NP Connection at CVMI end
DC -
Galvanic connection to CVMI board
Max. lenght 0.5 m

© ABB Ltd - 34 -
§ HVD Features:
ð 3 voltage inputs
ð High voltage insulation
§ Measures the DC voltages. Results are needed for example DTC
control and overvoltage protection
Block diagram of the HVD and SVA board
© ABB Ltd Page 34

Inverter
Current and Voltage Measurement
§ DC voltage measurement (HVD) A6:
§ Current measurements & overcurrent Overcurrent
protection (Hardware protection) A4: 2 Communication
§ 2 optical PPCS channels to INT board Overvoltage Channels to INT
to transfer measurement results
§ 2 optical output connected to INT-board
for the status of overcurrent and overvol-
tage detection (low active)
X8: Not used X8

X7
X7: Common rail current
measurement from X6
In case of
INU 2 (I2C 1_3) X4
double INU
X6: Current measurement X3
INU 2 (I 2INU1_3)
X4: Not used

© ABB Ltd - 35 -
X3: Current measurement

INU 1 (I 1INU1_3)
§ CVMI Features
§ 2 analogue voltage inputs
§ 5 analogue current inputs (3 used in ACS 5000)
§ 10 bit ADC
§ Overcurrent detection
§ Overvoltage detection (not used in ACS 5000)
§ 3 PPCS links (2 used in ACS 5000)
§ 8 Mbit/s transfer rate
§ High voltage insulation
§ Overcurrent detection
The overcurrent detection compares the analogue values of
current input I3-I6 with predefined threshold values. The state
of the overcurrent detection is signaled by optical output A6;
light means no overcurrent detected
© ABB Ltd Page 35

Inverter
Current measurements in Double drive
Phase
W
Phase
V
Phase
U
© ABB Ltd - 36 -
2INU 1INU
© ABB Ltd Page 36

Inverter
Current and Voltage Measurement
§ Scaling Subprints adjusting the current and voltage levels of the analogue
inputs according to the unit.
Current scaling subprint (SCA)

© ABB Ltd - 37 -
Voltage scaling subprint (SVA)
© ABB Ltd Page 37

Inverter
Short circuit detection
§ In parallel to every INU di/dt choke a VLSCD board is installed. The
VLSCD board is a passive board, which is detecting voltage applied to the
di/dt choke. During this time a fibre-optic signal is sent to control.
§ VLSCD = Voltage Level & Short Circuit Detection – Board
VLSCD
+DC
AC PHASE
NP
-DC
DC
VLSCD
Optical fibre to PINT board

© ABB Ltd - 38 -
Optical fibre to INT board
Introduction:
§ VLSCD is a pure analogue device which performs short circuit
detection through the supervision of the dropping voltage on the
DC
chokes (Ls1, Ls2).
§ Each time when one of the IGCTs of the upper side is turned on
there is a voltage on the Vls1 choke equal to the positive DC bus
voltage during the commutation time and each time when one
of
the IGCTs of the lower side is turned on there is a voltage on the
Vls2 choke equal to the negative DC bus voltage during the
commutation time.
§ If this voltage remains more than a certain allowable time (6 -
10µs),
a short circuit has occurred. The supervision of this signal is
made in the INT interface board and the supervision time is
programmed in the EPLD.
§ If signal does not appear every 50ms, when inverter operates with
sufficient load current
-> VLSCD fault detection
§ Optical output signal lights more or less at the same frequency
than
inverter switching frequency.
© ABB Ltd Page 38
Inverter
IGCT Power Supply (IPS)
§ The IGCT Power Supply (IPS) is used for supplying IGCT and
control boards, which are on MV potential.
§ The four output channels are insulated from the input side and from
each other.
§ The IPS supplies four unregulated AC-voltages or rectified DC-
voltages
§ IPS secondaries are supplying the control HW in NP potential and
the IGCTs. The IPS has 4 separate secondary outputs.
© ABB Ltd - 39 -
§ Input voltage: 230 VAC or 90 – 350 VDC

§ Four output channels (potential free)
§ Each channel includes either an unregulated DC-output (30 – 40
VDC) or an unregulated AC output (30 – 40 VAC, rectangular, 70
kHz)
§ Output power: 280 W (70 W per channel)
§ Fiber-optic status signal
§ Medium voltage insulation primary / secondary (double insulation)
§ Medium voltage insulation secondary / secondary (function
insulation)
© ABB Ltd Page 39

Inverter
§ In single drive each phase system consist three IPS, 2 IPS supplying
the eight IGCTs of the same phase. Third IPS supplies the IPS dual
voltage sub board which feeds the INT, EAF and CVMI boards of
the same phase
§ In case of double INU there is 2 IPS in the 2INU (per phase)
IPS1 IPS2 IPS1 IPS2 IPS3
GU2.3 +20 VDC
GU1.2 +20 VDC
GU1.4 +20 VDC
GU2.1 +20 VDC
GU2.3 +20 VDC

GU1.1 +20VDC
GU1. 2 +20VDC
GU1.3 +20VDC
GU1. 4 +20VDC
GU2. 1 +20VDC
GU2.2 +20VDC
GU2.4 +20VDC
GU1. 1 +20VDC
GU1. 3 +20VDC
GU2. 2 +20VDC
GU2. 4 +20VDC
To BCU 1_3
Voltage sub board
To LSU 1_3
To BCU 1_3
© ABB Ltd - 40 -
2INU 1INU
© ABB Ltd Page 40

Inverter
§ The optical feedback, the IPS failure supervision, is connected to the
INT board and turns the light off when the required power on the
secondary side can no longer be supplied or when the output voltage
is out of specification.
IPS
© ABB Ltd - 41 -
INT-board
© ABB Ltd Page 41

Inverter
IPS dual voltage subprint
§ The IPS single/dual voltage sub prints convert an unregulated input
to a regulated output voltage
§ Regulated Output voltage
§ Type R0120: +20 VDC
§ Type R0127: +27 VDC
§ Type R0124: +/- 24 VDC
§ Short circuit proof
§ LED fault indication
§ Input Range 30 - 40VDC
© ABB Ltd - 42 -
© ABB Ltd Page 42

© ABB Ltd
ABB
© ABB Ltd - 43 -
ACS 5000 Training
Page 43

G740 Inverter Unit Rev

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ABB ACS 5000 Training

ACS 5000 Service & ACS 5000

© ABB Ltd Page 1

Upon completion of this part the student will be able to

© ABB Ltd Page 2

§ Three splitted dc-links

© ABB Ltd Page 3

Inverter Unit 12 MVA, 6.9 kV (single INU)

18 MVA, 6.9 kV (double INU)

24 MVA, 6.9 kV (double INU)

§ Voltage Source Inverter Multilevel-Fuseless (VSI-MF)

© ABB Ltd Page 4

Hard coupled Phase module V

The main components of the Inverter Unit are :

§ 3 Phase modules called PEBB (Power Electronic Building

© ABB Ltd Page 5

© ABB Ltd Page 6

The main components of the phase module are :

© ABB Ltd Page 7

n Creating one line to line motor voltage

© ABB Ltd Page 8

Current flow according to princible above:

© ABB Ltd Page 9

Current flow according to princible above:

© ABB Ltd Page 10

Current flow according to princible above:

© ABB Ltd Page 11

Current flow according to princible above:

© ABB Ltd Page 12

Current flow according to princible above:

© ABB Ltd Page 13

n The line to line voltage at basic switching

© ABB Ltd Page 14

© ABB Ltd Page 15

© ABB Ltd Page 16

© ABB Ltd Page 17

§ Chokes protect diodes and IGCTs from excessive di/dt.

© ABB Ltd Page 18

© ABB Ltd Page 19

Clamping Dcl Dcl

Capacitor Dcl Dcl

H-brigde with clamping circuit

The main components of the phase module are :

© ABB Ltd Page 20

§ Circuit formed by diode (Dcl1, Dcl2), resistor (Rcl1, Rcl2) and

© ABB Ltd Page 21

© ABB Ltd Page 22

© ABB Ltd Page 23

RC-IGCT (used in ACS 5000)

Integrated Gate Commutated Thyristor + Integrated freewheeling diode

IGCT + Freewheeling diode

Integrated Gate Commutated Thyristor + separate Freewheeling diode

© ABB Ltd Page 24

2uF Dnp 2uF Dnp

§ Connecting the charging transformer between DC-link neutral point

NP phase 3 NP phase 2 NP phase 1

© ABB Ltd Page 25

DC bus charging sequence = 20 s

MCB order close

§ At the beginning Main Circuit Breaker (MCB) is off

§ Precharging the DC-link (capacitors) is done by using charging circuit

§ MCB is on and dc-voltage reach it’s nominal level.

© ABB Ltd Page 26

INT board PEC-INT Main