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Table of Contents
List of Figures 9
List of Tables
13
Chapter 1 - Overview 1.1 1.2 1.3 1.4 1.5 1.6 Introduction Modular design Technological highlights Standard applications Benefits for the customer CE marking
15 15 16 17 18 19 21
Chapter 2 - Types and applications 2.1 2.2 2.2.1 2.2.2 2.2.3 2.3 2.3.1 2.3.2 2.3.3 General The ACS 6000 drive types Single-motor drives Multi-motor drive Redundant configurations Application examples Marine propulsion and thruster drives Rolling mill applications Mining applications
23 23 23 23 25 27 27 27 30 35
Chapter 3 - Functional description, operation 3.1 3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.3 3.3.1 3.3.2 3.4 3.4.1 General Standard control functions Direct torque control Motor control functions Active rectifier control functions Application control functions Operation and diagnostics Local and remote operation Standard diagnostic functions Standard protection functions General
37 37 37 37 41 42 42 44 44 49 49 49
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3.4.2 3.4.3 3.4.4 3.4.5 3.5 3.6 Protection functions related to drive system Internal converter protection functions External protection functions Manually initiated protection functions Other features Optional features 50 52 52 53 53 54
Chapter 4 - Hardware design, technology and configuration 4.1 4.2 4.2.1 4.2.2 4.2.3 4.3 4.4 4.4.1 4.4.2 4.4.3 4.5 4.6 4.6.1 4.6.2 4.7 Overview Technology Common DC bus Fuseless design IGCT power semiconductor Cabinet layout Cabinet design Mechanical design Electromagnetic compatibility (EMC) Safety aspects Busbars and grounding Auxiliary supply system 3-phase supply 3-phase supply and separate UPS for control power Cooling system
55 55 55 55 60 60 61 62 62 63 63 64 65 65 66 67
Chapter 5 - Hardware design, description of converter units 5.1 5.2 5.3 5.3.1 5.3.2 5.3.3 5.4 5.4.1 5.4.2 5.4.3 5.5 5.5.1 5.5.2 5.6 5.6.1 5.6.2 Overview Available modules Line supply unit (LSU) Overview 12-pulse LSU 6-pulse LSU Active rectifier unit (ARU) Overview Main components Circuit diagram Inverter unit (INU) Overview Circuit diagram Capacitor bank unit (CBU) Overview Main components
69 69 69 70 70 70 73 74 74 76 77 78 78 79 80 80 80
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5.6.3 5.7 5.7.1 5.8 5.8.1 5.8.2 5.9 5.9.1 5.9.2 5.9.3 5.9.4 5.9.5 5.9.6 5.9.7 5.9.8 5.9.9 5.10 5.10.1 5.10.2 5.11 5.11.1 5.11.2 5.11.3 5.12 5.12.1 5.12.2 5.12.3 5.13 5.13.1 5.13.2 5.13.3 5.14 5.14.1 5.14.2 5.14.3 5.15 Circuit diagram Terminal unit (TEU) Overview Control unit (COU) Overview Main components Water cooling unit (WCU) Overview Water cooling system WCU types and sizes Main components Cooling control Raw water connection Technical data Options for WCU Air-to-air heat exchangers Customer interface unit (CIU) Overview Main components Input filter unit (IFU) Overview Main components Circuit diagram Voltage limiter unit (VLU) Overview Main components Circuit diagram Resistor braking unit (RBU) Overview Main components Circuit diagram Braking chopper unit (BCU) Overview Main components Circuit diagram Excitation Unit (EXU) 82 82 82 83 83 86 87 87 87 88 91 92 93 93 93 93 94 94 95 96 96 96 97 97 97 98 99 99 99 100 101 101 101 101 102 102
Chapter 6 - Control system and process interfaces 6.1 6.2 6.2.1 6.2.2 6.3 6.3.1 Overview Hardware and structure of the control system Hardware Configuration examples Local control devices CDP local control panel
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6.3.2 6.4 6.4.1 6.4.2 6.5 6.5.1 6.5.2 6.5.3 6.6 6.6.1 6.6.2 6.6.3 6.6.4 6.6.5 6.6.6 6.7 CDP control panels, control switches and indicator lamps Fieldbus interfaces Fieldbus types Signals Hardwired process I/Os Standard S800 I/O modules Customer control signals Interface configurations Control software Control software structure Operating system Motor and rectifier control software Fixed application software FCB application software Panel application software Control options 110 114 114 115 118 118 119 119 122 122 123 123 123 124 124 124
Chapter 7 - Engineering information 7.1 7.2 7.3 7.3.1 7.3.2 7.4 7.5 7.6 7.7 7.8 7.8.1 7.9 General Main circuit breaker Main transformer Main transformer for ARU Main transformer for LSU ARU synchronization transformer Asynchronous motor requirements Synchronous motor requirements Excitation supply Selection of power cables Power cable dimensioning Control cabling
125 125 125 126 126 126 126 126 126 127 127 127 128
Chapter 8 - Installation guidelines 8.1 8.2 8.3 8.4 8.5 8.6 8.6.1 8.6.2 8.6.3 8.6.4 General Ambient conditions Transport Installation site requirements Raw water flanges Power cable installation, grounding and shielding Sealing system for power cable entry Connecting ARU to supply transformer Connecting LSU to supply transformer Connecting motor to INU
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8.7 8.8 Equipment grounding Installation of auxiliary power and control cables 137 138
Chapter 9 - Ordering information 9.1 9.2 9.2.1 9.2.2 9.2.3 9.3 9.4 9.5 9.6 General Drive selection Required application data Configuration procedure Configuration rules Type code Option list External system data Technical data
141 141 141 141 141 142 142 142 142 143
Chapter 10 - Options 10.1 10.2 10.3 10.4 10.5 10.5.1 10.5.2 Converter hardware Options for WCU Converter software Service and diagnostics Optional customer interfaces I/O with option CIW1 (standard software) I/O with option CIW2 and CIW3 (project specific SW) 10.5.3 I/O with option CIUe 10.5.4 AC 80 / AC 800 controller 10.6 Marine version 10.7 Transportation, installation and commissioning 10.8 Training 10.9 Testing 10.10 Documentation
145 145 146 147 147 150 150 150 150 150 151 153 153 153 154
Index
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List of Figures
Figure 1-1 Figure 1-2 ACS 6000, typical marine configuration with air-to-air heat exchanger ACS 6000, typical standard configuration with active rectifier without air-to-air heat exchanger Typical examples for basic configurations Single-motor drives, basic configurations Single-motor drive, SD type, example with active rectifier Example of a standard multi-drive configuration Example of system configuration for offshore drilling rig Redundant main propulsion system Configuration for a service vessel Hot rolling mill train: overview Rougher mill train Reversing steckel mill Sendzimir mill Mine hoist Overland conveyor DTC block diagrams DTC: typical dynamic speed response DTC vs. PWM: Typical torque response times Typical ramp shapes Setting the control panel to local / remote Start sequence with ARU Start sequence with LSU Stop and off sequence with ARU Stop and off sequence with LSU Emergency off sequence Stall region of the motor Common DC bus principle Converter principle diagram Phase voltage created by ARU Vector control principle Active rectifier control block diagram IGCT ACS 6000 basic configuration with LSU ACS 6000 basic configuration with active rectifier and input filter unit Arrangement of busbars "AC safe line" auxiliary concept 3-phase auxiliary supply and AC UPS 15
Figure 1-3 Figure 2-1 Figure 2-2 Figure 2-3 Figure 2-4 Figure 2-5 Figure 2-6 Figure 2-7 Figure 2-8 Figure 2-9 Figure 2-10 Figure 2-11 Figure 2-12 Figure 3-1 Figure 3-2 Figure 3-3 Figure 3-4 Figure 3-5 Figure 3-6 Figure 3-7 Figure 3-8 Figure 3-9 Figure 3-10 Figure 3-11 Figure 4-1 Figure 4-2 Figure 4-3 Figure 4-4 Figure 4-5 Figure 4-6 Figure 4-7 Figure 4-8 Figure 4-9 Figure 4-10 Figure 4-11
16 17 24 25 26 28 29 30 31 32 33 34 35 36 38 40 40 41 44 45 46 47 48 48 51 56 57 57 58 59 60 61 62 64 66 66
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Figure 4-12 Figure 4-13 Figure 5-1 Figure 5-2 Figure 5-3 Figure 5-4 Figure 5-5 Figure 5-6 Figure 5-7 Figure 5-8 Figure 5-9 Figure 5-10 Figure 5-11 Figure 5-12 Figure 5-13 Figure 5-14 Figure 5-15 Figure 5-16 Figure 5-17 Figure 5-18 Figure 5-19 Figure 5-20 Figure 5-21 Figure 5-22 Figure 5-23 Figure 5-24 Figure 5-25 Figure 5-26 Figure 5-27 Figure 5-28 Figure 5-29 Figure 5-30 Figure 5-31 Figure 6-1 Figure 6-2 Figure 6-3 Figure 6-4 Figure 6-5 Figure 6-6 Figure 6-7 Figure 6-8 Figure 6-9 3-phase auxiliary supply and DC UPS Principle diagram of the water cooling circuit Cabinet layout of 12-pulse LSU Circuit diagram of 12-pulse LSU Cabinet layout of 6-pulse LSU with IRU Circuit diagram of 6-pulse LSU with IRU ARU cabinet layout Phase module with IGCTs ARU local control and monitoring equipment ARU circuit diagram 3 and 5 MVA Units 7, 9 and 11 MVA INUs Circuit diagram of 7, 9 and 11 MVA INUs Circuit diagram of 3 and 5 MVA units CBU cabinet layout CBU circuit diagram TEU (1000 mm wide) COU control swing frame installed in a TEU (typical configuration) Reverse side of COU doors (typical configuration) Principle illustration of water cooling circuit WCU - closed to atmospheric pressure Principle flow diagram of a WCU with a closed circuit WCU open to atmospheric pressure Flow diagram of WCU with open circuit Roof heat exchangers CIU, typical cabinet layout IFU cabinet layout IFU circuit diagram VLU cabinet layout VLU circuit diagram RBU cabinet layout RBU circuit diagram BCU circuit diagram Single-motor drive with ARU Single-motor drive with ARU (example with water-cooled EXU) Single-motor drive with LSU Multi-motor drive with ARU Multi-motor drive with double ARU Single-motor drive with double ARU and double INU CDP control panel ARU control panel INU control panel 67 67 71 72 73 74 75 76 77 77 78 79 79 80 81 82 83 84 85 87 88 89 90 91 94 95 96 97 98 99 100 101 102 105 106 107 108 108 108 110 111 112
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Figure 6-10 Figure 6-11 Figure 6-12 Figure 6-13 Figure 6-14 Figure 6-15 Figure 6-16 Figure 7-1 Figure 8-1 Figure 8-2 Figure 8-3 Figure 8-4 Figure 8-5 Figure 8-6 Figure 8-7 Figure 8-8 Figure 8-9 Figure 8-10 Figure 8-11 Figure 10-1 Figure 10-2 Figure 10-3 Figure 10-4 Figure 10-5 Figure 10-6 Figure 10-7 Figure 10-8 Figure 10-9 Control panel on additional control units Grounding switch on CBU S800 I/O station S800 I/O configuration of an ACS 6000 single drive ACS 6000 single-motor drive with option CIW1 Typical ACS 6000 multi-motor drive with option CIU2 Software block diagram of the AMC controller Excitation transformer schemes for multi-motor drives Cabinets with base frame and without door handles Cabinets with base frame and marine-type door handles Cabinets without base frame Space requirements (dimensions in mm) Flanges Power cable entry with roxtec sealing system ARU side cabling LSU side cabling INU side cabling TEU, connection to system ground Control cable entry with roxtec sealing system Output switch types Leakage sensor Typical DriveWindow display ACS 6000 with DriveMonitorTM installed in a console S800 I/O configuration with AC 80 / AC 800 Marine version Door arrester Roof fixings Roof connecting pieces 113 114 118 119 120 121 122 127 130 130 130 131 133 134 135 136 137 138 138 145 146 148 149 151 151 152 152 153
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List of Tables
Table 2-1 Table 3-1 Table 4-1 Table 6-1 Table 6-2 Table 6-3 Table 6-4 Table 7-1 Case study: power requirements of a sendzimir mill with ACS 6000 DTC versus current vector control IGCT technology compared to GTO and IGBT Fieldbus adapters Basic data exchange between AMC and process control: analog and binary inputs Basic data exchange between AMC and process control: analog and binary outputs S800 I/O modules Control cable requirements 34 39 61 114 116 117 118 128
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Chapter 1 - Overview
1.1 Introduction
The Technical Catalog describes the main electrical, mechanical and environmental features of the ACS 6000, the modular medium voltage drive for megawatt class applications in the 3 kV range. In addition, the Catalog illustrates the various options available for the drive and offers advice on selecting a motor and drive combination. It also provides useful installation tips. For general information on the ACS 6000 refer also to the ACS 6000 Brochure. The ACS 6000 is a medium voltage, variable speed frequency converter for high power induction and synchronous motors. The ACS 6000 covers a power range from 3 to 27 MVA and delivers output frequencies from 0 to 75 Hz.
Figure 1-1
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Figure 1-2
ACS 6000, typical standard configuration with active rectifier without air-to-air heat exchanger
1.2
Modular design
The ACS 6000 features a modular design based on standardized cabinet units. Each unit is dedicated to a specific function. The units are combined according to the required output power, motor configuration and process needs.
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Chapter 1 - Overview
Figure 1-3
Refer to Chapter 5 - Hardware design, description of converter units for identification of the units. Depending on the application, four different types of configurations are available (Figure 1-3): 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
1.3
Technological highlights
The following features distinguish the ACS 6000 from other converters on the market:
Direct Torque Control (DTC) enables highest torque and speed control performance ever achieved in medium voltage drives. DTC allows: Torque response times up to 10 times faster than conventional control methods using flux vector or pulse width modulation Minimal torque ripple
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Acccurate static speed and torque control. The Integrated Gate Commutated Thyristor (IGCT) 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.
The Active Rectifier Unit (ARU) 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.
The Line Supply Unit designed for two-quadrant operation maintains the power factor at 0.95 in the whole operating range. Multiple rectifiers and motor inverters can be connected to the same DC bus. This allows several drives to be combined 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.
1.4
Standard applications
The ACS 6000 provides the optimum solution for marine and industrial medium voltage drive applications. Typical fields of applications are: Marine Oil and gas Metals and mining General industry Main propulsion systems Thruster drives Compressors Pumps Rolling mills Mine hoists Overland conveyors Crushers and mineral mills Variable speed fans and pumps Pump storage plant drives
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Teststand.
Chapter 1 - Overview
1.5
Maximum availability
Low energy costs are achieved by: Minimal reactive power consumption
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The reactive power demand of the drive can be neglected by using ARU or LSU (see Chapter 4 - Hardware design, technology and configuration, Power factor control). The supply system needs only to be designed for effective power consumption. Additional 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 the 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.
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 are achieved due to water cooling: Easy wearing parts, such as fans and bearings needed in air-cooled systems, are not used.
Maintenance on running system: What you need is what you get The maintenance or replacement of redundant cooling pumps can be done on the running system. Air-to-air heat exchanger.
Customer requirements are precisely met. The flexible design with standard converter units and the well proven control platform allow the optimum configuration of the drive system. Modular design: Converter rating fits exactly customer requirements. Each configuration consists of well proven and certified converter units, 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 engineered systems due to standardized procedures and documentation.
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Well proven ABB AC drives control platform:
Chapter 1 - Overview
Configurable application software and standard interfaces for hardwired I/Os allow optimum integration into the industrial environment. Interfaces for all common fieldbus types are available for communication 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 requirement of the relevant EC directives.
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Chapter 2 - Types and applications
2.1 General
This chapter provides information about the modular structure of the ACS 6000. A number of typical examples from the marine and industrial field illustrate how the modular concept of the ACS 6000 is applied to provide the optimum converter configuration for high-power applications. The design of the ACS 6000 is characterized by the common DC bus. Depending on the individual drive configuration and the power demands of the process, multiple LSUs or ARUs are connected together with motor inverters to the same DC bus.
2.2
The basic configurations for single-motor applications of up to 11 MVA are shown in Figure 2-1. The rectifier is connected to the input transformer (LSU, a and c in Figure 2-1, or ARU, b and d in Figure 2-1). The INU feeds the motor. For smoothing the DC voltage, a CBU is connected to the DC bus. In case of a synchronous motor, an EXU is added to the configuration (see bottom of Figure 2-1).
The TEU and COU and the WCU complete the basic converter. BCU, RBU and/or VLU are optional.
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B
Aux. power Mains Synchronization voltage Aux. power
Mains
Mains
D
Aux. power Excitation power
Figure 2-1
The figure above shows the basic configurations of the ACS 6000 for induction motors (A,B) and synchronous motors (C,D). Single drives with multiple units For powerful single drives, rectifier and inverter units are used in parallel: LSUs or ARUs on the supply side and two INUs on the motor side.
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Figure 2-2 shows a typical example of a parallel configuration with multiple units: Two INUs and a 12-pulse supply with two ARUs for a synchronous motor
Depending on the application, other configurations with LSU and/or induction motor are possible. The dimensions of CBU and WCU depend on the rated converter power.
Mains Synchronization voltage Aux. power Excitation power
Figure 2-2
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Multi-motor drives have the advantage that the number of MCBs and converter transformers is reduced. Motors with the same or different power rating are fed from the common DC bus of the converter (see Figure 2-3, Figure 2-6 and following). Synchronous and induction motors can be part of the same line-up. Depending on the type of rectifier, a maximum of 4 or 5 INUs can be connected. Multi-motor drives require a separate COU for each motor and an EXU for each synchronous motor. In applications with parallel driving and braking, the ratings of rectifier unit, main circuit breaker and transformer can be reduced substantially when only the net-power demand has to be drawn from the supply busbar (see Table 2-1).
Mains
Figure 2-3
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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 28. The configuration shows a standard drive for a redundant main propulsion system with a tandem motor for marine applications. The DC bus can be split with an ISU and the converter units are arranged symmetrically with two separate feeders.
2.3
Application examples
Figure 2-4 shows a typical example for a dynamically positioned offshore drilling rig. It is equipped with four ACS 6000 single drives.
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Mains Aux. power
Figure 2-4 Propulsion and thruster for shuttle and service vessels
Figure 2-5 shows an example of a redundant main propulsion system where the power system can be split. The main propeller (Azipod or 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 a common DC bus (Azipod and propeller units) are provided.
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Mains
Mains
Aux. power
Mains
Mains
Aux. power
Aux. power
Figure 2-6 shows a typical configuration for a service vessel with two main 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.
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Mains Aux. power Aux. power
Mains
Figure 2-6
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.
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Edger mill Rougher mill
Crop shear
A typical rougher mill consisting of edger, rougher and crop shear is shown in Figure 2-8. 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.
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Aux. power Excitation power
A typical converter arrangement for a reversing steckel mill is shown in Figure 2-9. 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.
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The two main mill drives with synchronous motors are equipped with ACS 6000 single drives. To provide sufficient overload capabilities each motor is fed by two INUs.
Mains
Synch.reference
Aux. power
The sendzimir cold rolling mill consists of a mill stand and two tension reels as shown in Figure 2-10. 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.
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Aux. power Excitation power
Mains
Synch. reference
Figure 2-10 Sendzimir mill Table 2-1 Case study: power requirements of a sendzimir mill with ACS 6000
Estimated power requirement Main drive Tension reel 1 Tension reel 2 Total supply with individual drives Total supply with common DC bus 4 MW with 200% overload capability 4 MW with 200% overload capability 4 MW with 200% overload capability 3 x 4 MVA with 200% overload capablity Converter rating 9 MVA 9 MVA 9 MVA 3 x 9 MVA = 27 MVA
2 x 7 MVA = 14 MVA
a. Dimensioning factor
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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 especially when starting from zero speed Full four-quadrant operation with active rectifier Small footprint Power factor of 1 (negligible voltage drop) Input filter unit (IFU). The optional unit is used when the drive is supplied by a weak network. The IFU also reduces the harmonic voltages injected to the network. Mine hoists Figure 2-11 shows an example of a mine hoist with double INU for very low speed and high overload capability.
Mains Synchronization voltage Aux. power Excitation power
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Overland conveyor
Long overland conveyors may have an overall length of several kilometers. In terrains with long declining sections high braking capabilities are needed and the drive is mainly operating in regenerative mode. Regenerative braking requirements can be met optimally by using the ACS 6000 with active rectifier. Figure 2-12 shows an example with four parallel induction motors driving an overland conveyor belt.
Mains
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Chapter 3 - Functional description, operation
3.1 General
This chapter provides information about the standard control, monitoring and protection functions of the ACS 6000. A description of the basic operation and diagnostic devices is included as well. The description of the related control hardware, software and customer interfaces can be found in Chapter 6 - Control system and process interfaces. Links to other documents Summary of references to linked documents in this chapter: Appendix - Technical data
3.2
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Torque reference Speed reference Speed control Torque reference controller Torque and flux comparator Switching logic
Actual speed
Asynchronous motor
Torque reference Speed reference Actual speed & position Speed control Torque reference controller Torque and flux comparator Switching logic
Synchronous motor
Figure 3-1
The measured motor currents and DC link voltages are inputs to an adaptive motor model which calculates exact values of torque and flux every 25 s. 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 s. Switching takes place whenever required while in conventional Pulse Width Modulation (PWM) controlled drives switching is done only in predetermined patterns which results in slower response times. 3.2.1.2 DTC performance and benefits DTC provides excellent speed control accuracy even without pulse encoder feedback. It virtually eliminates the excitation of any torque resonances on the motor shaft by avoiding explicitely assigned PWM modulation frequencies. Control of the frequency converter is immediate and smooth under all conditions and the audible noise in the motor is considerably reduced compared to other control methods.
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The torque response times are up to ten times faster than with conventional control methods such as current vector control. This results in minimum torque ripple and most accurate static speed and torque control. DTC versus current vector control Table 3-1 DTC versus current vector control
Direct torque control (asynchronous motor) Motor control variables Switching is based on core motor variables flux and torque
Direct torque control (synchronous motor) Switching is based on core motor variables flux and torque
Vextor control
Switching is based on the separate control of magnetic field and torque producing current components Mechnical speed is essential. Requires shaft speed and postion (measured or estimated)
Shaft speed and position are not required (only high performance applications as for example in the mining and metal industry require speed encoders Each inverter switching process is determined separately (every 50 s)
Mechnical speed is essential. Requires shaft speed and postion (measured or estimated)
Inverter switching is based on average references to a pulse width modulator resulting in delays in response and unnecessary switching Torque step rise time closed loop: 10 to 20 ms sensorless: 100 to 200 ms
Other major features and benefits of DTC are: High speed accuracy: typically 0.1% of nominal speed (without speed encoder) High torque performance Full torque at zero speed and very fast torque step response time (typical ~ 3 milliseconds) Robust control method DTC is extremely robust and compensates disturbances and inaccuracies on supply, motor and load side. This avoids nuisance tripping and increases the reliability of the ACS 6000. Low audible motor noise and negligible low torque ripple by avoiding dedicated modulation frequencies Minimum inverter switching losses at maximum control performance.
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DTC provides fast control without requiring high switching frequency. This is possible because control is not based on a fixed PWM modulation frequency. Instead, switching takes place exactly when needed. Conventional PWM control would need >10 kHz switching frequency for equivalent performance. DTC performance Figure 3-2 illustrates a typical dynamic speed response caused by a load step.
PWM with encoder Static speed error Dynamic speed error 0.01 % 0.3 % sec DC drive with encoder 0.01 % 0.3 % sec DTC with encoder 0.01 % 0.2 % sec
Torque (kNm)
Figure 3-2
In many applications there is no need for speed and position encoders to meet the performance requirements. See Table 3-1 and Appendix Technical data for detailed information. The example in Figure 3-3 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: response times at 70% speed DTC: 3 ms PWM flux vector: 1020 ms PWM: > 150 ms (scalar control) Torque: DTC PWM
Figure 3-3
For more information on DTC, see Technical Guide No. 1 Direct Torque Control (3AFY 58056685 R0025).
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3.2.2 Motor control functions
3.2.2.1 Speed control features Accurate speed control
The speed controller is based on a PID algorithm. The steady state speed control error is around + 0.1% of motor nominal speed (without pulse encoder), which satisfies most industrial applications. The dynamic speed control error is typically + 0.20.5 % sec. at 100% torque step. The dynamic speed error depends on speed controller tuning. Refer to Figure 3-2 for corresponding figures including pulse encoder.
Figure 3-4
It is possible to adjust acceleration and deceleration times and to select different ramp shapes: S-curve ramps are ideal for applications, where a smooth transition from one speed to another is required. Linear ramps for converters requiring long acceleration/deceleration periods and where S-curve ramps cannot be used.
By applying a torque reference instead of a speed reference, the converter maintains a specific motor torque value; the speed adjusts automatically to the required torque. Speed and torque performance figures meet or exceed the requirements of IEC 61800-4.
Parameter adjustable minimum and maximum limits can be set for speed and torque output.
3.2.2.2 Direct torque control features Direct torque control related settings By setting the appropriate parameters, maximum and/or minimum limits can be defined for: Frequency Motor current Inverter overload
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The motor model produces exact actual values of torque and flux, based on measured motor current and DC link voltages. The excitation current is controlled in a way that the power factor of synchronous motors is 1. Rotor speed and position of a synchronous motor are monitored continuously to improve static and dynamic performance of the motor control loop. As an option, a pulse encoder for speed monitoring is available for asynchronous motors.
3.2.4.2 Network related functions Main circuit breaker control The main circuit breaker should be closed by the converter only. This 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. All opening and closing commands to the main circuit breaker are monitored 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: No protection trip is active.
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No emergency off or stop is active. The DC bus grounding switch is open. 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 close command from the converter to the main circuit breaker 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 the main circuit breaker is tripped. Conditions for opening the main circuit breaker: 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 open command 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 switchgear. If this status feedback does not arrive after a preset time, the tripping coil of the main circuit breaker is activated. Several external main circuit breaker trip commands (e.g. transformer and motor monitoring relays, process trips, etc.) can be integrated into the hardwired tripping loop. 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.
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3.3
When the converter is switched to local control, local operation from the ON/OFF pushbuttons on the converter front door and from the CDP control panel is possible. In local operation mode no remote control command will be accepted. When the converter is switched to remote control, local operation from the pushbutton on the front door of the control unit and from the CDP 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. The local emergency off buttons on the front doors of the control unit(s) remain active in local and in remote mode. The converter can be started and stopped either manually from the local control panels or from remote overriding control.
Remote control
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3.3.1.2 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 via the local CDP control panel or from remote as soon as the DC link is charged. ARU control INU control
NOT RDY ON
NOT RDY ON
- No fault - Aux supply on - Grounding switch ...open - ARU RDY ON - WCU ok - Doors closed - etc. ON (pushbutton) remote: ON
RDY ON
RDY ON
- MCB closed
RDY RUN
RDY REF
RDY REF
Figure 3-6
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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
RDY REF
Each INU can be stopped individually via the local control panel or via the remote control system. The converter can be switched off by pressing the local OFF button.
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ARU control
RDY REF
INU control
RDY REF Local: STOP (CDP INU) Remote: RUN Ramp down speed Stop modulation
RDY REF
RDY RUN
Stop modulation
Discharge DC link
RDY ON
RDY ON
Figure 3-8
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INU control
RDY REF
Local: STOP (CDP INU) Remote: RUN Ramp down speed Stop modulation
RDY RUN
Discharge DC link
RDY ON
The converter is switched off immediately if the Emergency OFF button is pressed. ARU control
RDY REF
INU control
RDY REF
Emergency OFF
Stop modulation
NOT RDY ON
NOT RDY ON
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3.3.2 Standard diagnostic functions
Actual signal monitoring
Three signals can be displayed simultaneously on the control panel. 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.
3.4
3.4.1 General
All relevant system variables within the ACS 6000 are continuously monitored by the control system. Preprogrammed protection functions ensure that these variables remain within certain limits 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 an alarm or fault condition occurs in the converter or related equipment, it will be indicated with an error message on the control panel or, as an alternative, on the DriveWindow error display. Two error message levels are used in the ACS 6000: Alarm (warning): an alarm does not shut down 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 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. If an ARU initiates a trip, all INUs connected to the same DC bus trip as well and the main circuit breaker is opened.
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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).
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Torque Stall region
Tm.a
Stall frequency
f (Hz)
Figure 3-11 Stall region of the motor The protection is activated if all of the following conditions are fulfilled simultaneously: Output frequency is below the set stall frequency. Actual torque exceeds stall torque limit (torque limit level can be set by the user). Frequency and torque levels from the previous conditions 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 a preset level, a trip is initiated. Overfrequency If the frequency of a motor exceeds a preset level, the corresponding converter will trip. Motor phase loss Inverter phase currents are monitored. In case of a phase loss, 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 hardware. Excitation protection The excitation circuit of synchronous motors is protected against overcurrent, overload, supply network disturbance and earth fault (isolation measurement is used for earth fault detection). Ground fault A ground fault is detected in two ways:
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The neutral point voltage is monitored against ground. 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.
Monitoring functions of the cooling circuit include the following: The status of the water cooling pumps and the water level in the expansion vessel (only open cooling circuits) are monitored. Temperature, pressure and conductivity of the cooling water are continuously measured and compared to preset limits. If a preset limit is exceeded, an alarm or (if the condition persists) a trip is initiated. The flow in the water treatment circuit is measured continuously. The reaction of the drive on insufficient flow can be set by parameter.
Communication monitoring
The status of all communication links is monitored. If a fault is detected, a trip is initiated.
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Supply transformers
Optional inputs are provided for group alarm and fault signals (optional customer interfaces, see Chapter 6 - Control system and process interfaces, 6.5 Hardwired process I/Os).
3.5
Other features
The converter software version, the production date of the individual version, and the serial number can be displayed. The doors of the units containing medium voltage equipment (terminal sections, rectifier and inverter sections, capacitor banks) are equipped with an electromechanical interlocking system which ensures that the door of these units cannot be opened as long as the DC link of the converter is energized. For details refer to Chapter 4 - Hardware design, technology and configuration, 4.4 Cabinet design. The user can prevent unwanted parameter adjustment by activating the parameter lock.
Parameter lock
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3.6
Optional features
See Chapter 10 - Options for information.
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Chapter 4 - Hardware design, technology and configuration
4.1 Overview
This chapter provides a description of the standard power, control and cooling hardware of the ACS 6000 including cabinet design, busbars and grounding, the auxiliary supply system and the cooling system. Links to other documents Summary of references to linked documents in this chapter: ACS 6000 Outline Drawings Appendix - Technical data Appendix - Applicable codes and standards
4.2
Technology
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=
Rectifier
=
Inverter
=
Rectifier Inverter
Figure 4-1
Depending on the application, the following converter modules can be combined on the common DC bus: Active self-commutated 6-pulse Voltage Source Inverter (VSI) This device allows four-quadrant operation and can be connected as Active rectifier unit (ARU) or inverter unit (INU). See Section 4.2.1.2 Active rectifier and inverter units. 6-pulse diode rectifier for applications without power feedback to the line: Line Supply Unit (LSU). 4.2.1.2 Active rectifier and inverter units The ARU and INU unit is a self-commutated 6-pulse, three-level voltage source inverter with IGCT technology: The ARU can operate in all four-quadrants and can be combined to 12-pulse or 18-pulse systems. Several INUs can be combined to supply higher power motors or to connect several motors to the same DC bus.
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Operating principle
The ARU rectifies the transformer secondary AC voltage to the level of the DC link. The DC link voltage is kept constant by the ARU by drawing energy from the line when in driving mode and by feeding energy back to the line when in braking mode (see Figure 4-2). Energy flow in driving mode
AC line voltage Voltage imposed by ARU DC link voltage
ARU =
INU =
ARU and INU have identical design. 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 mode the ARU behaves like an INU in braking mode and vice verca as shown in Figure 4-4. 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 4-3. The resulting ARU voltage patterns define the transformer secondary voltage. The transformer primary side is connected to the supply network. U ARU
Figure 4-3
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The voltage difference between transformer primary and secondary side is applied to the leakage inductance and determines the transformer current. The current can be controlled (see Figure 4-4) by varying phase angle and magnitude of the transformer secondary voltage. trans ARU line 1 ARU q trans trans line line 1 ARU line line
Block diagram
ARU
1 ARU
Phasor diagram
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.
Since the ARU voltage pattern does not correspond to a sinewave, harmonics are induced in the voltage. To minimize the lowest harmonics, the pulse patterns are optimized. The optimized patterns are stored in a lookup table and the controller selects the correct pattern depending on the system conditions. The ARU control block diagram is shown in Figure 4-5. Refer to Chapter 5 - Hardware design, description of converter units, 5.4 Active rectifier unit (ARU) for further details.
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DC link voltage control Q ref UDC ref Vector control Modulator (optimized pulse patterns) IA,B,C Meas. UDC+ UDC-
UA UB UC
Synchronization (PLL)
The Line Supply Unit (LSU) features a diode rectifier which is available in two versions: 6-pulse diode rectifier 12-pulse diode rectifier consisting of two standard 3-phase rectifiers
Using the configuration rules for the ACS 6000, LSUs with the same power rating can be operated in parallel to achieve 24-pulse rectification. The LSU provides the following features: Two quadrant operation Operation at constant power factor of about 0.95 Fuseless converter protection.
For further details on the LSU refer to Chapter 5 - Hardware design, description of converter units, 5.3 Line supply unit (LSU). 4.2.1.4 Advantages Modularity The ACS 6000 modularity is based on the common DC bus principle. With the available INUs (3, 5, 7, 9 and 11 MVA) any motor or combination of motors in the range of 3 .. 27 MVA can be supplied. Various combinations of synchronous and asynchronous motors are possible. The number of system components as well as the footprint can be reduced.
Multi-motor configurations
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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.
Figure 4-6
IGCT
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The IGCT combines the gate commutated thyristor together with the gate unit as integrated unit. Table 4-1 IGCT technology compared to GTO and IGBT
High voltage IGBT High switching frequency Low switching losses Snubberless Modular design IGCT advantages High blocking voltage High switching frequency Low conduction losses Snubberless Proven reliability Allows compact and modular equipment design Simple topologies with low parts count Snubberless
GTO thyristor Switching technology High blocking voltage Low on-stste losses
Equipment design
4.3
Cabinet layout
The modular design of the ACS 6000 allows the standardized converter units (e.g. LSU, ARU, INU, WCU) to be combined optimally for a specific application with minimum engineering effort. Figure 4-7 and Figure 4-8 are examples for typical cabinet layouts. A detailed description of each unit is provided in Chapter 5 - Hardware design, description of converter units.
LSU
INU
CBU
WCU
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ARU
TEU/COU
INU
CBU
VLU
WCU
ACS 6000 basic configuration with active rectifier and input filter unit
4.4
Cabinet design
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4.4.1.5 Compliance with international standards The design of the ACS 6000 fulfills the requirements of international standards listed in Appendix - Applicable codes and standards.
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4.5
Cable entry from bottom Connecting point of system ground Figure 4-9 AC busbars Arrangement of busbars
PG to PE connection in CBU
Incoming feeder and motor cables are connected to their corresponding busbars inside a TEU. In multi-motor drives several TEUs are part of the drive line-up. The incoming busbars are interconnected with the line rectifier unit (ARU or LSU: depending on drive configuration) and the outgoing busbars with the motor inverter(s) (INU). The busbars can be identified by their phase designations.
DC busbars
The DC busbars connect the line rectifiers (ARU or LSU) with motor inverter(s) (INU) and CBU. In multi-motor configurations up to four DC busbar arrangements can be installed. The busbars are mounted in the upper part of the converter and are marked with DC (+), DC (-) and DC (NP). It is important that the drive is properly grounded to maintain safety and to ensure smooth functioning of the equipment. For this reason, the drives grounding cable must be securely tied to the grounding system of the installation site (system ground). The ACS 6000 is equipped with a continuous grounding busbar (marked PE, Protective Earth) which is installed through the length of the converter in the bottom area of the cabinets (see Figure 4-9). The grounding cable must be connected to the grounding busbar of the converter at only one point: at the busbar inside the TEU closest to the CBU.The connection must be in compliance with local regulations.
Safety ground
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Power ground
Cable shields must be connected to the converter to ensure proper operation. A separate busbar (Power Ground, PG) is installed for this purpose. The busbars of power ground and protective earth are connected with each other inside the CBU which has the grounding switch mounted on the front door. The connection is made in the factory already.
4.6
The total auxiliary power can be supplied to the drive by a 3-phase AC power supply. Depending on the requirements for safe shutdown and the use of the ride-through functions of the ACS 6000, the control power must be supplied separately and backed up by an uninterruptible power supply (UPS). The ACS 6000 can be ordered with one of the following auxiliary power interfaces to accommodate these requirements: 3-phase supply 3-phase supply and separate UPS with AC output 3-phase supply and separate UPS with DC output
In addition, a separate power supply is needed for Each excitation unit if present in the line-up Optional converter space heaters (110 / 230 VAC).
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Charging Unit
Charging Unit
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380 - 690 VAC 110 / 220 VDC from ext. UPS (DC safe line)
Charging Unit
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 maintenance, even if the system is running. In case of redundant configurations two separate water cooling circuits can be provided. Refer to Chapter 5 - Hardware design, description of converter units for further details on the cooling system.
Cooling pumps Heat exchanger Figure 4-13 Principle diagram of the water cooling circuit
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Chapter 5 - Hardware design, description of converter units
5.1 Overview
This chapter provides a description of each individual unit. Detailed information is given on the cabinet layout, the available versions as well as on the monitoring and protection devices. Links to other documents Summary of references to linked documents in this chapter: ACS 6000 Outline Drawings Appendix - Technical data Appendix - Applicable codes and standards
5.2
Available modules
The following ACS 6000 units are available: Line Supply Unit (LSU), see section 5.3 Line supply unit (LSU) 6 and 12-pulse diode rectifier Input Reactor Unit (IRU), see section 5.3 Line supply unit (LSU) For transformerless installations in combination with a 6-pulse LSU. IRU comprises the input reactor as a current limiter and a terminal section for the power supply cables. Active Rectifier Unit (ARU), see section 5.4 Active rectifier unit (ARU) 6-pulse self-commutated voltage source inverter Inverter Unit (INU), see section 5.5 Inverter unit (INU) 6-pulse self-commutated voltage source inverter for power ratings of 3 and 5 MVA with control part and power cable termination incorporated in one cabinet. 6-pulse self-commutated voltage source inverter for power ratings of 7, 9 or 11 MVA (parallel connection for higher output power possible). Capacitor Bank Unit (CBU), see section 5.6 Capacitor bank unit (CBU) Contains the DC link capacitors. Terminal Unit (TEU), see Section 5.7 Terminal unit (TEU) For power cable termination. Control Unit (COU), see section 5.8 Control unit (COU) Water Cooling Unit (WCU), see section 5.9 Water cooling unit (WCU)
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Customer Interface Unit (CIU), see section 5.10 Customer interface unit (CIU) Houses additional input and output interfaces.
Input Filter Unit (IFU), see section 5.11 Input filter unit (IFU) Harmonic filter for ARU, use depends on supply network configuration.
Voltage Limiter Unit (VLU), see section 5.12 Voltage limiter unit (VLU) Dynamic DC voltage limiter
Resistor Braking Unit (RBU), see section 5.13 Resistor braking unit (RBU) DC chopper with integrated resistors
Braking Chopper Unit (BCU), see section 5.14 Braking chopper unit (BCU) DC chopper to be used in combination with external resistors
Excitation Unit (EXU) see section 5.15 Excitation Unit (EXU) 6-pulse thyristor bridge or AC power controller
5.3
5.3.1 Overview
The LSU rectifies the AC line voltage and supplies electrical energy to the DC link capacitors of the CBU (see section 5.6 Capacitor bank unit (CBU)). The available LSUs can be distinguished by pulse number and power rating.
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Pulse transformer
Snubber resistors
Water inlet tube Safety ground busbar Figure 5-1 Cabinet layout of 12-pulse LSU
12-pulse LSUs are available for the following power ratings: 7 MVA 9 MVA 14 MVA
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Using the configuration rules for the ACS 6000 (see Chapter 9 - Ordering information, 9.2 Drive selection), LSUs with the same power rating can be operated in parallel to achieve 24-pulse rectification and/or to increase the drive power. 5.3.2.1 Main components The LSU consists of the following main components (refer also to Figure 5-2): 12-pulse diode rectifier Snubber circuit limiting the rate of the voltage rise (dv/dt) across the diodes and the crowbar thyristors di/dt limiting reactors defining the current rise in the thyristor crowbar Thyristor crowbar, a protection circuit which is activated should a short circuit occur in the converter. By applying protection firing the rectifier is shorted to prevent further damage of the converter. Pulse interface board generating the firing pulses sent to the crowbar thyristors via the pulse transmitters Diode rectifier monitoring unit for short circuit detection in the rectifier (indirect method to detect faulty rectifier diodes)
Rnp DC (NP)
2L1 2L2 2L3 di/dt choke DC (-) Diode rectifier Snubber circuit Diode rectifier monitoring unit Pulse interface board To / from INU
Figure 5-2
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5.3.3 6-pulse LSU
The 6-pulse LSUs are designed for applications without converter transformer and are always operated with a line-side Input Reactor Unit (IRU) as illustrated in Figure 5-3. The main purpose of the IRU is to limit the input current and to improve the Total Harmonic Distortion (THD) of the supply voltage. IRU and 6-pulse LSU are available for the following power ratings: 5 MVA 7 MVA
IRU
LSU
Terminal section
Snubber resistors
Pulse transformer
Water inlet tube Safety ground bar 3-phase reactor Figure 5-3 5.3.3.1 Main components The IRU/LSU consists of the following main components (refer also to Figure 5-4): IRU LSU 3-phase input reactor Terminal section for input cables 6-pulse diode rectifier Cabinet layout of 6-pulse LSU with IRU
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Snubber circuit limiting the rate of the voltage rise (dv/dt) across the diodes and the crowbar thyristors di/dt reactors limiting the current rise in the thyristor crowbar Thyristor crowbar, a protection circuit which is activated should a short circuit occur in the converter. The rectifier is shorted to prevent further damage of the converter by applying protection firing. Pulse interface board generating the firing pulses sent to the crowbar thyristors via the pulse transmitters Rectifier monitoring unit for short circuit detection in the rectifier (indirect method to detect faulty rectifier diodes)
di/dt choke DC (-) Diode rectifier with snubber circuit Diode rectifier Monitoring unit To / from INU
Figure 5-4
5.4
5.4.1 Overview
The ARU controls the energy flow to the DC link and keeps the DC link voltage at a constant level irrespective of changes in the supply network. The ARU is designed as a self-commutated voltage source inverter in 6-pulse, 3-level topology for the following power ratings: 7 MVA 9 MVA 9 MVA continuous (11 MVA/20 seconds every 60 seconds) 11 MVA (continuous operation)
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The units differ in their electrical ratings but have the same mechanical dimensions. A maximum of three ARUs can be connected in parallel for drive power ratings up to 27 MVA resulting in 12-pulse or 18-pulse rectifier configurations.
Water tubes
Anti-saturation equipment
Figure 5-5
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Rear busbar stubs IGCTs Figure 5-6 Antiparallel diodes Phase module with IGCTs Cooling water inlet
Gate unit power supply (GUSP), an electrically isolated unit mainly supplying the IGCTs with auxiliary power Clamping circuit with di/dt chokes and freewheeling diodes protecting the circuit from excessive rises in current EMC filter protecting the transformer from excessive voltage slopes (dv/dt is limited to 1.7 kV/ms) 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. Fast short circuit detection (FSCD) monitoring the main power circuit for short circuits
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Anti-saturation equipment (ASE) preventing the converter transformer from 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 to the Interface board via fiber optic cables.
Rclamp
L1,2,3
EMC filters
DC (NP)
Rclamp
DC (-) HVD board
GUSP
ASE board
CMVI board
INT board
Figure 5-7
L1 L2 L3
DC (NP)
DC (-)
Phase modules
Clamping circuit
Figure 5-8
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5.5
5.5.1 Overview
The INU converts the DC voltage to the AC motor voltage. The selfcommutated, 6-pulse, 3-level voltage source inverter allows four-quadrant operation. The available INUs are distinguished by their power rating and design. The compact 3 and 5 MVA units as illustrated in Figure 5-9 with the vertical alignment of the inverter phase modules have their Control Unit (COU) and the Terminal Unit (TEU) for the motor cables incorporated in different sections of the same cabinet. Refer to sections 5.8 Control unit (COU) and 5.7 Terminal unit (TEU) for further information on COU and TEU.
Terminal unit (TEU) behind control unit Figure 5-9 3 and 5 MVA Units
The bigger 7, 9 and 11 MVA units as presented in Figure 5-10 have the same layout and components as the Active Rectifier Unit (ARU) except for the anti-saturation equipment which is not needed for motor operation. Refer to 5.4 Active rectifier unit (ARU) for details. Depending on the application, up to five INUs with different power ratings can be connected to the same DC bus.
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Phase modules
DC (NP)
L1 L2 L3
DC (-)
Clamping circuit
Phase modules
EMC filter
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DC (+)
L1 L2 L3 DC (NP)
DC (-)
Clamping circuit
Phase modules
EMC filter
5.6
5.6.1 Overview
The CBU smoothes the intermediate DC voltage and decouples the rectifier from the inverter. The CBU contains DC link capacitors, a charging unit and a grounding switch. The CBU is available in two different sizes depending on the power rating of the converter (size 1 for converters up to 9 MVA and size 2 for converters rated for 9 to 14 MVA). For high power converters, up to two CBUs of the same size can be installed on the same DC link.
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Braking Chopper Unit (BCU) Grounding switch, a safety switch to ground the DC bus of the converter The grounding switch can only be closed if the DC link capacitors have been discharged. Optional coupling device for monitoring the insulation resistance
Cable duct
Connection PE - PG Water inlet tube Safety ground busbar Figure 5-13 CBU cabinet layout
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Grounding switch
PE
5.7
5.7.1 Overview
Mains and motor cables of the ACS 6000 converter are connected to their corresponding busbars inside Terminal Units (TEU). TEUs are designed for top or bottom cable entry. TEUs are available either as separate cabinets or they are integrated into other cabinets. The number and type of TEUs present in a line-up depends on the type and the power ratings of the line rectifier (LSU or ARU) and the power ratings of the motor inverter (INU): The TEU for 5 and 7 MVA, 6-pulse Line Supply Units (LSU) is incorporated into the cabinet of the Input Reactor Unit (IRU) (see Figure 5-3). The TEU for 3 and 5 MVA Inverter Units (INU) is built into the same cabinet as the inverter (see Figure 5-9). The TEU used in combination with 12-pulse LSUs and power ratings of 7, 9 and 14 MVA and in combination with INUs/ARUs and power ratings of 7 and 9 MVA shares a separate cabinet with a Control Unit (COU). See Figure 5-15 and Figure 5-16 (Figure 5-15 shows the Terminal Unit with the swing frame of the Control Unit opened). The width of the cabinet (600 mm or 1000 mm) is determined by the number of line rectifiers and/or motors to be supplied via one TEU. If required by the configuration of the ACS 6000, cabinets without a Control Unit can also be present in the line-up.
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Separate TEU for 11 MVA continuous power INUs (no combination with other units).
Ground terminals for grounding set AC busbars Phase designation Roxtec frame Power cable entry section (bottom)
Power ground busbar Safety ground busbar Ground terminals for grounding set Swing frame of Control Unit (COU) open Figure 5-15 TEU (1000 mm wide)
5.8
5.8.1 Overview
The COU incorporates the hardware for control, monitoring and protection functions of the line rectifier or the inverter it is assigned to. The COU also includes the interfaces to the local control panel on the front door and to a higher-level process control system.
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Position (gray) encoder interface* 24 VDC power supply units Speed encoder interface* Main circuit breaker control board S800 I/O modules 24 VDC distribution terminals
Safety relays of emergency off circuit INU operation prevention devices* Timer relays* Auxiliary relays*
Auxiliary relays for main circuit breaker control Insulation monitor* 230 VAC distribution terminals Thermostats for: cabinet fan unit cabinet temperature Auxiliary contactors
PE busbar
* option, depends on the configuration of the frequency converter ** only converters with ARU (Active Rectifier Unit)
Figure 5-16 COU control swing frame installed in a TEU (typical configuration)
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2
Fan unit Fan unit
Local control panel (see section 6.5.1 for details) 24 VDC distribution terminals
Branching unit*
INT board** AMC board*** Pocket for documentation INT board**** AMC board
* option, depends on the configuration of the frequency converter ** only converters with parallel ARUs (Active Rectifier Unit) *** only converters with ARU (Active Rectifier Unit) ****only converters with two INUs supplying a motor
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The hardware components of a COU are mounted on a swing frame. The type and number of the fitted components are determined by the configuration of the ACS 6000. The size of the swing frame and the mounting position of the components depend on the cabinet the swing frame is installed in. See Figure 5-9 for the illustration of the swing frame in 3 and 5 MVA Inverter Units and Figure 5-16 for the illustration of the swing frame in a TEU. The number of COUs in a line-up depends on the configuration of the ACS 6000: A separate COU is assigned to an ARU in combination with 3 and 5 MVA INUs. As a standard, an ARU in combination with 7, 9 and 11 MVA INUs shares the COU of the first INU. Depending on the selected options and the configuration of the converter, a separate COU is used for the ARU. When a LSU is part of the converter, all rectifier and line related functions are implemented in the COU of the first Inverter Unit as well. A separate COU is assigned to each INU supplying its own motor. Several INUs supplying one motor share the same COU.
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5.9 Water cooling unit (WCU)
5.9.1 Overview
The heat losses from the main power components are dissipated to the exterior by the water cooling system of the converter (see section 5.9 Water cooling unit (WCU)). Additionally, depending on the power demand of the converter, roofmounted air-to-air heat exchangers are used to remove the heat from nonwater cooled components inside the power sections of the converter (see section 5.9.9 Air-to-air heat exchangers).
Figure 5-18 Principle illustration of water cooling circuit The WCU is equipped with two pumps and a water-to-water heat exchanger. Deionized / distilled water is circulated continuously dthrough the components to be cooled to a water-to-water heat exchanger which transfers the heat to an external cooling circuit. The cooling unit is accessible for maintenance, even if the converter is in operation. Water cooling circuits The water cooling system consists of three circuits: 1. The internal circuit filled with deionized / distilled water transfers the heat losses of the main power components to the water-to-water heat exchanger in the WCU. The water treatment circuit is part of the internal circuit and continuously purifies the cooling water of the internal circuit to keep the conductivity at a low level. The circuit also includes a fill-up valve. The external water circuit containing raw water transfers the heat losses from the water-to-water heat exchanger to the exterior.
2.
3.
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Cable duct
Water pumps Heat exchanger Ion exchange vessel Control swing frame
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Expansion vessel
5 1
Deaeration vessel
2 6
Drain hose 12
1 2 3 4
from converter pipe DN 80 from EXU hose nipple 26.5 to EXU hose nipple 26.5 to converter pipe DN 80
5 6 7 8
outlet to cooler counter flange DN 50 / ANSI 2" inlet from cooler counter flange DN 50 / ANSI 2" raw water outlet counter flange DN 50 / ANSI 2" raw water inlet counter flange DN 50 / ANSI 2"
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Cable duct
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Flow diagram
2 3
Drain hose 12
4 5
Drain hose Make-up water 12 ISO-R 1/2
6
Drain hose 12
1 2 3 4
thread ISO-Rp 1/2 from converter pipe DN 80 from EXU hose nipple 26.5 thread ISO-Rp 1/2
5 6 7 8
to EXU hose nipple 26.5 to converter pipe DN 80 raw water outlet counter flange DN 80 / ANSI 3" raw water inlet counter flange DN 80 / ANSI 3"
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Control and monitoring devices for temperature, pressure and conductivity of the internal cooling water One water pump circulating the water through the internal cooling circuit, one standby pump Water-to-water heat exchanger transferring the heat from the internal cooling circuit to the external raw water circuit Expansion vessel for pressure compensation Water conditioning circuit with ion exchange vessel purifying the cooling water of the internal circuit and thus maintaining the water conductivity at the desired low level Three-way valve controlling the flow through the heat exchanger Optional hardwired process I/O interfaces. SeeChapter 6 - Control system and process interfaces, 6.5.1 Standard S800 I/O modules for more information.
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When both pumps are selected to run and the running pump fails, the pump in standby is automatically switched on. Isolation valves allow the decommissioned pump to be disconnected from the water cooling circuit and serviced during converter operation. Three-way valve The three-way valve controls the flow through the heat exchanger and is opended or closed depending on the internal water temperature. The valve ensures that the water flow in the external circuit remains constant whereas at the same time the flow through the water-to-water heat exchanger varies depending on the required cooling water.
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Optional I/Os for transformer and motor monitoring functions for singlemotor drives are integrated into the customer interface unit (CIW) inside the WCU.
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Filter resistors
Filter capacitors
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5.11.3 Circuit diagram
TEU
L 1 TEU L 2 TEU L 3 TEU
IFU
ARU
L 1 ARU L 2 ARU L 3 ARU
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Air-cooled resistors
IGCTs
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5.12.3 Circuit diagram
VLU
DC (NP)
INU
INTBoard
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IGCTs
Water-cooled resistor
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5.13.3 Circuit diagram
RBU
DC (NP)
INU
INTboard
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DC (+) VLSCD board
1
DC (NP)
2
VLSCD board DC (-)
INU
INTboard
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Chapter 6 - Control system and process interfaces
6.1 Overview
This chapter provides a description of the control hardware and software of the ACS 6000, as well as the hardwired and fieldbus interfaces that are at the customers disposition. Furthermore, the available control options are explained as well. Links to other documents Summary of references to linked documents in this chapter: Standard and Optional I/O Configuration (3BHS123187 ZAB E01)
6.2
6.2.1 Hardware
AMC controller The control system is based on ABBs well proven Application and Motor Controller (AMC). Fitted with a 150 MHz Motorola DSP processor, the controller features two PPCS and eight DDCS communication channels. PPCS (Power Plate Communication System) and DDCS (Distributed Drive Control System) are acronyms for serial communication protocols tailored for data transfer via fiber optic cables, namely with: Converter and excitation control interfaces Higher-level process control systems via advant or fieldbus adapters, see section 6.4 Fieldbus interfaces I/O devices, see section 6.5 Hardwired process I/Os Service tools (e.g. DriveWindow), see Chapter 10 - Options.
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Configuration rules
The number of AMC controllers used in the control system depends on the configuration of a converter: A separate AMC controller is installed in a converter with a single Active Rectifier Unit (ARU), or in a converter with a group of ARUs connected in parallel (see Figure 6-1). This line-side AMC controller is not part of the control system if the converter is equipped with a Line Supply Unit (LSU) (see Figure 6-3). An additional AMC controller is used for each Inverter Unit (INU) supplying its own motor, or a group of INUs supplying one motor (see Figure 6-4 and Figure 6-6).
Control units
The line-side AMC controller and the AMC controller of the first INU are mounted in the same Control Unit (COU). In multi-motor drives this is always COU1. The line-side AMC controller is installed separately (COU0), when the converter is equipped with an ARU in combination with 3 and 5 MVA INUs. The AMC controller of each additional INU supplying its own motor is mounted in its own Control Unit. The control units of a multi-motor line-up are serially numbered and can be identified by their COU name plates. The location of the COUs in the project specific line-up can be seen in the mechanical drawings.
Control panel
An AMC controller is always connected to a CDPcontrol panel which is mounted on the front of the corresponding COU. The CDP control panel serves as a basic user interface for monitoring, control and operation and changing of parameters. The communication of the AMC controller with the CDP control panel is accomplished via a RS-485 link. For detailed information on the functions of the CDP control panel, refer to 6.3 Local control devices. AMC controllers communicate with each other through an INTerface board (INT) which incorporates a software (Power Feed Forward [PFF]) for optimized data transfer. The same type of INT board serves as a branching unit between an AMC controller and the INT boards of ARUs connected in parallel, or between an AMC controller and the INT boards of INUs supplying one motor. For this purpose, a software is utilized which facilitates data branching (PPCS Unit for Branching [PUB]). INT boards for these communication links are located inside the first COU. Data between an AMC controller and the control hardware in ARU or INU are exchanged through INT boards as well. An additional board is mounted in each ARU and INU.
INTerface boards
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General control tasks
General control, protection and monitoring tasks regarding the whole converter are always implemented in the AMC controller of the first INU (also referred to as Master INU). These tasks include control and monitoring of: Main Circuit Breaker (MCB) Grounding isolator / charging unit Door interlocking Water cooling
Excitation unit
If an INU controls a synchronous motor, the reference value for the excitation current is provided by the AMC controller associated to the INU. The excitation current controller is implemented on the CCB board located in the Excitation Unit (EXU). Signals between AMC controller and CCB board are transmitted via fiber optic cables (see Figure 6-2 for illustration).
INT
INT
Figure 6-1
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The following Figure 6-2 provides a detailed view of the interconnection of the control hardware of a Control Unit, an Active Rectifier Unit and an Inverter Unit.
COU
PC tool Process I/O
Rectifier control
Process control system Control panel Fieldbus adapter ABB advant control RS 485
Inverter control
Process control system
PC tool
Fieldbus adapter
AMC
AMC
NTAC GRB
Rotor position
VA...VC
SYN
INT
ARU
INT
FT-link
INU
INT
CCB PAI
VNP to ground
EXU
MUB MUI
HVD + CVMI
V to ground VDC+ NP VDC-
HVD + CVMI
VDC-
GDR
Excitation supply
IA...IC
IA...IC
IDC
vDC
Figure 6-2
When equipped with a LSU instead of an ARU, all rectifier and line related functions of the ACS 6000 are implemented in the AMC controller of the COU (COU1 in multi-motor drives) assigned to the first INU. The following Figure 6-3 illustrates how the control hardware of a singlemotor drive with a LSU is interconnected.
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COU
Inverter control
PC tool
Control panel
Fieldbus adapter
S800
Process I/O
AMC
LSU
FT-link
INU
INT
PPCS FSCD FSCD VDCDiode monitoring VNP to ground PPCS IOC IA...IC
PINT
HVD + CVMI
EAF
VDC+
IM
PG (optional) To NTAC (optional)
In addition to the single-motor drive described before, a further AMC controller for the second INU is added to the control system in a separate COU2. With each additional INU added, the control system is basically extended by another control unit which is equipped with an AMC controller, and by an INTboard and the inverter control hardware located in the inverter.
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COU2 AMC AMC
COU1 AMC
INT
INT INU2
INT
As illustrated in Figure 6-5, multiple ARUs are controlled by only one AMC board which communicates with the line rectifiers via the same type of INT board as used for the communication between the AMC boards in the examples above.
COU1 AMC AMC COU2 AMC
INT
INT ARU1
INT INU2
INT
Figure 6-5 Single-motor drive with double ARU and double INU
The example below shows that double INUs supplying one motor also require only one AMC controller which communicates with the inverter units via the same type of INT board as the AMC controller assigned to the line rectifiers.
COU AMC AMC
INT
INT
INT ARU1
INT INU2
INT
Figure 6-6
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6.3 Local control devices
The panel allows the operator: to enter startup data into the drive, to control the drive by setting reference values and by giving start, stop and direction commands, to display three actual values at a time, to display and set parameters, to display information on the last 64 fault events.
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Selection and changing buttons Reset button Local, remote button Forward, reverse buttons
Figure 6-7
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The bulbs of lamps and illuminated pushbuttons can be tested with the lamp test function. The lamp test is activated via the CDP control panel by setting a control parameter. An emergency off switch is installed on each contol unit. The emergency off switches affect the whole drive when activated (see Figure 6-9 and Figure 6-10). The grounding switch is installed on the capacitor bank unit (CBU). The switch can only be actuated if released by the converter (see Figure 6-11). When the grounding switch is released, the indicator lamp on the door of the CBU lights up. The indicator lamp has an integrated momentary pushbutton to test the lamp. The lamp lights up when the pushbutton is pressed.
Control Panel - displays ARU status messages - displays ARU alarm and fault ..messages - resets alarm and fault messages
Figure 6-8
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Control panel - starts and stops the motor - displays status messages of the converter - displays alarm and fault messages - resets alarm and fault messages
Illuminated pushbuttons - OFF opens the main cicuit breaker - ON closes the main cicuit breaker Alarm / fault lamp - ALARM: flashing light - FAULT: permanent light Emergency off reset switch
EMERGENCY OFF
Emergency off switch - prevents starting when actuated at standstill - main circuit breaker opens and DC link discharges when actuated during operation
Figure 6-9
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Control panel - starts and stops the motor - displays status messages of the converter - displays alarm and fault messages - resets alarm and fault messages
Emergency off switch - prevents starting when actuated at standstill - main circuit breaker opens and DC link discharges when actuated during operation Figure 6-10 Control panel on additional control units
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Indicator lamp with lamp test function - signals when grounding switch can be turned into position grounded - used to test the lamp. Lamp lights up when cap is pressed Grounding switch, grounds the converter
6.4
Fieldbus interfaces
Fieldbus adapters
Adapter typea ABB FCI NPBA-12 NMBA-01 NMBA-01 NETA-01 CI858 (external adapter)
A fieldbus adapter is mounted on the swing frame of a control unit and is directly connected to an AMC controller via fiber optic cables. If the converter is equipped with several AMC controllers, as in multi-motor drives, data are not transmitted via a single fieldbus interface. Owing to the modular structure of the converter, the higher-level control system communicates directly with each AMC controller. Each AMC controller is connected to a separate fieldbus adapter.
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6.4.2 Signals
Communication with the AMC 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.
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Note: The following tables are for general information only and should not be used for engineering purposes. The project relevant signal and parameter tables depend on the final drive configuration and on the selected control and communication hardware. Table 6-2 Basic data exchange between AMC and process control: analog and binary inputs
Target Value Description
Reference 1, speed reference in rpm Reference 2, torque reference Command to close MCB Command to open MCB Emergency OFF command (coast stop + MCB off) Emergency STOP command (emergency stop ramp) Command for state "Ready Reference" Normal stop (current controller is blocked) Normal operation Ramp generator output is set to zero (torque stop) Enable speed ramp Speed ramp is stopped, actual setpoint is frozen Enable setpoint Ramp generator input is set to zero (ramp stop) Fault reset (rising edge) Accelerate to inching speed reference 1 Stop inching (brake as fast as possible) Accelerate to inching speed reference 2 Stop inching (brake as fast as possible) AC 80 / AC 800 controller requests to control the drive No control from remote Select external control location 2 Select external control location 1 Process stop requested
Bit 1
Bit 2
Bit 3
Bit 4
INU
1 0
Bit 5
INU
1 0
Bit 6
INU
1 0
Bit 7
1 0 1 0
Bit 8
Bit 9
INU
1 0
Bit 10
1 0
Bit 11
1 0
Bit 12
1 0
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Table 6-3
Basic data exchange between AMC and process control: analog and binary outputs
Target Value Description
INU INU INU/ ARU INU/ ARU INU/ ARU INU/ ARU INU/ ARU INU 1 0 1 0 1 0 1 0 1 0 1 0
Actual speed in rpm (integer: 20000= max. speed). Used by the speed controller Actual torque (integer: 10000= nominal torque) Drive ready for ON command (ready to close MCB) Not ready Drive ready for RUN command Not ready Drive ready for reference value Operation inhibited Drive tripped No fault Emergency OFF active (coast stop + MCB off) Emergency STOP active (emergency stop ramp) Switching ON is inhibited Alarm or warning is active Setpoint and actual value within margins Actual value differs from setpoint Drive controlled by overriding control system Drive controlled via CDP panel or DriveWindow Actual speed equals or exceeds limits Actual speed within limits External control location 2 selected External control location 1 selected
Bit 1
Bit 2
Bit 3
Bit 4
Bit 5
Bit 6
INU/ ARU INU/ ARU INU/ ARU INU/ ARU INU/ ARU INU/ ARU
1 0 1 0 1 0 1 0 1 0 1 0
Bit 7
Bit 8
Bit 9
Bit 10
Bit 11
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6.5
Figure 6-12 S800 I/O station Table 6-4 S800 I/O modules
No. of channels 16 16 16 8 relays 8 4 8 8 4 I/O rating 24 VDC 48 VDC (on request only) 24 VDC 230 VAC 0(4)...20 mA, 0(2)...10 V, 0(4)...20 mA, 0(2)...10V, +/- 20 mA, +/- 10 V PT100 resistance measurement 0(4)...20 mA, 0(2)...10 V, 0(4)...20 mA, 0(2)...10V, +/- 20 mA, +/- 10 V
I/O module type DI 810 DI 811 DO 810 DO 820 AI 810 AI 820 AI 830 AO 810 AO 820
Analog input
Analog output
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TB 820 bus modem
Communication between an AMC controller and I/O modules is accomplished by a bus modem via a fiber optic link using the standard DDCS protocol. Data between a bus modem and I/O modules is transmitted through the S800 module bus. standard AMC controller
CH 7
standard
option CIW1
DDCS S800 module bus TB 820 S800 module bus DI 810 DO 810 DI 810 TB 820 DI 810 DO 820 AI 820 TB 820 AI 820 DI 810 AO 820 DO 820 AI 820 COU1 WCU S800 module bus
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6.5.3
Interface configurations
6.5.3.1 General The ACS 6000 can be integrated into all common industrial control environments. Typically, it is connected to the process control system via a fieldbus interface. The standard ACS 6000 provides all hardwired I/O signals to protect itself. Optional I/Os can be provided to monitor the transformer and the motor. 6.5.3.2 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) and the local control panel.
ABB
Option CIW1 This option provides additional five S800 I/O modules with predefined I/Os for transformer and motor auxiliaries.
Option CIW2 and CIW3 This option provides a programmable AC 80 / AC 800 controller and the same I/O configuration as option CIW1. Additionally, the five I/O modules can be replaced by other S800 modules. These I/Os can be allocated to specific functions depending on the users needs.
The resulting optional signals are listed in section Chapter 10 - Options, 10.5 Optional customer interfaces.
Fieldbus (e.g. Profibus) Fieldbus (e.g. Modbus) Service tool (*)
e.g. DriveWindow
INU
TEU /COU
WCU
Control panel
AMC processor
Position / speed encoder (*)
S800
S800
Standard I/O (*) optional equipment Inverter/MCB/ Emergency off/ charging WCU monitoring Customer I /O (*)
Figure 6-14 ACS 6000 single-motor drive with option CIW1 6.5.3.3 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) and the local control panel.
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Option CIU1
The hardware of this option corresponds to option CIW1. The five predefined S800 I/O modules are placed in a separate cabinet (see Chapter 5 - Hardware design, description of converter units, 5.10 Customer interface unit (CIU)). Option CIU2 and CIU3 Options CIU2 and CIU3 correspond to option CIW2 and CIW3. S800 I/O modules and AC 80 / AC 800 are mounted in a separate cabinet (see Chapter 5 - Hardware design, description of converter units, 5.10 Customer interface unit (CIU)). Option CIUe This option is used for engineered interfaces. The additional I/O modules are placed in a separate cabinet (see Chapter 5 - Hardware design, description of converter units, 5.10 Customer interface unit (CIU)). The resulting optional signals are listed in section Chapter 10 - Options, 10.5 Optional customer interfaces.
Fieldbus (e.g. Profibus) Fieldbus (Modbus)
AMC processor
AMC processor
AMC processor
WCU monitoring
Inverter 2 I/O
Inverter 3 I/O
Figure 6-15 Typical ACS 6000 multi-motor drive with option CIU2
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6.6
Control software
INU control
AMC AMCOS (AMC Operating System) Function block library Motor control + Fixed application Speed controller
Fieldbus adapter Advant AC controller S800 process I/O Control panel Panel application FCB application program
AMC table
AMC AMCOS (AMC Operating System) Function block library Fieldbus adapter Advant AC controller Control panel FCB application program DC voltage and cos controller Rectifier control + Fixed application
ARU control
Panel application
Modulator interface
AMC table
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6.6.2 Operating system
The AMC Operating System (AMCOS) is a real-time multitasking system providing functions such as task scheduling and FLASH memory management as well as standardized interfaces to the AMC table and services for I/O communication and diagnostics. The AMC table contains data for motor, rectifier and application control functions including the process I/O image. The AMC table serves also as an interface for data interchange between different software groups.
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The Main State Machine (MSM) is a predefined program serving as the prime control place for drive control systems based on the AMC controller. The MSM is called up cyclically by the operating system and coordinates start, stop and fault sequences in ARU and INU. It determines the optimum reaction on any event or fault occurring in the converter.
6.7
Control options
See Chapter 10 - Options for information.
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Chapter 7 - Engineering information
7.1 General
This chapter describes the requirements for system components which are not included in the converter scope of supply. Further information on the requirements for system components are available in the following system component specifications: Links to other documents Summary of references to linked documents in this chapter: Appendix - Technical data Specification for Main Circuit Breaker (3BHS125149 ZAB E60) Requirements for Main Feeder and Transformer Protection (3BHS125149 ZAB E81) ARU Main Transformer Specification (3BHS125092 ZAB E01) Technical Requirement Specification (12-pulse LSU for single drives) (3BHS121185 ZAB E01) Technical Requirement Specification (24-pulse LSU) (3BHS121186 ZAB E01) Selection of Synchronization Transformers for ACS 6000 (3BHS125393 ZAB E01) ACS 6000 Asynchronous Motor Specification (3BHS211284 ZAB E01) ACS 6000 Asynchronous Motor Specification for non-ABB machines (3BHS 211984 ZAB D01) Metals Induction Motor Specification (3BHS254644 ZAB D01) ACS 6000 Synchronous Motor Specification (3BHS217607 ZAB E01) Metals Synchronous Motor Specification (3BHS254140 ZAB D01) ACS 6000 Power Cables Specification (3BHS125090 ZAB E01) Wiring and Busbar Specification (3BHS205465 ZAB E01)
7.2
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Refer also to Specification for Main Circuit Breaker (3BHS125149 ZAB E60) and Requirements for Main Feeder and Transformer Protection (3BHS125149 ZAB E81).
7.3
Main transformer
The ACS 6000 converter is fed from a main transformer providing sufficient 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.
7.4
7.5
7.6
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7.7 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 transformer 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 7-1. Excitation supply Excitation supply
Option A:
Option B:
EXU
EXU
EXU
EXU
EXU
EXU
Figure 7-1
7.8
The drive specific cable requirements are described in the following sections.
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Refer also to ACS 6000 Power Cables Specification (3BHS125090 ZAB E01).
7.9
Control cabling
Control cables Control cables should be provided in accordance with Table 7-1. Cable shields should be terminated on the ACS 6000 side only. Either single or multiple twisted pair cables may be used. Table 7-1 Control cable requirements General cable type
Twisted pair(s) - overall shield Twisted pair(s) - overall shield Twisted pair(s) - overall shield Twisted pair(s) - overall shield Twisted pair cable with separately shielded pairs and overall shield Twisted pair cable with separately shielded pairs and overall shield
Signal type
Analog input Analog input Digital input Digital output Speed encoder Position encoder
Cross-section
0.5 to 2.5 mm2 / AWG 20 to AWG 12 0.5 to 2.5 mm2 / AWG 20 to AWG 12 0.5 to 2.5 mm2 / AWG 20 to AWG 12 0.5 to 2.5 mm2 / AWG 20 to AWG 12 0.5 mm2 4 x (2+1) 0.5 mm2 4 x (2+1)
Synchronization cables
Synchronization cables are not applicable for ACS 6000 with line supply 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. Refer also to Wiring and Busbar Specification (3BHS205465 ZAB E01).
Cable marking
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Chapter 8 - Installation guidelines
8.1 General
This chapter provides all necessary instructions for transportation, requirements for the installation site as well as for the mechanical and electrical installation material. Links to other documents Summary of references to linked documents in this chapter: Appendix - Technical data ACS 6000 Outline Drawings Roxtec Cabinet Seals
8.2
Ambient conditions
Ambient conditions may require to derate the drive due to the presence of increased air temperature, cooling water temperature or altitude. Sufficient air flow must be available. Other ambient factors such as relative humidity, air contamination, shock and vibration must also be in compliance with stated maximum permissible levels. See Appendix - Technical data for load capacity derating factors and other requirements related to ambient conditions.
Converter enclosure
The standard IP protection classes for the converter enclosure according to IEC 60529 are given in Chapter 4 - Hardware design, technology and configuration, 4.4.1.2 IP rating and sound pressure level.
8.3
Transport
Transport units Each transport unit is mounted on a base frame. The base frame is a permanent fixture. The maximum length of the base frame is 5.7 m. The length of the transport units is specified 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. Lifting and moving Transport sections of a converter must always be lifted by crane with the cabinets in upright position. The lifting cables should be fixed to the cabinets and be at an angle as indicated in Figure 8-1 to Figure 8-3.
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30
Protect edges !
Figure 8-1
30
Figure 8-2
MAX.
120
Figure 8-3
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8.4 Installation site requirements
Foundation and floor levelling
Cabinets must be installed in upright position. The floor must be of non-flammable material, with a smooth and nonabrasive surface, protected against humidity diffusion, levelled and able to support the weight of the converter (min. 1000 kg/m2). 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. The exact dimensions of the line-up are stated on the mechanical drawings supplied with the drive. 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 8-4). The free space above must not be less than 700 mm for installation, cooling and explosion protection purposes. A minimum free space of about 1600 mm is recommended in front of the converter as an escape route. However, this distance might vary depending on local regulations.
Dimensions
Clearances
Figure 8-4
The dimensions in Figure 8-4 do not include space for cable and water entries (top and bottom entries possible). Dimensions must be specified when ordering the ACS 6000.
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The lengths of typical drive configurations are given in Appendix Technical data. 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 drawings). A protection against fire spreading, humidity, dust and penetration by animals must be forseen. Ventilation A part ot the heat losses are dissipated into the air. For this reason, the installation site must be ventilated to fulfill the requirements for ambient conditions as specified in Appendix - Technical data. The heat losses into the air depend on the power rating of the converter. Sufficient illumination of the electrical room has to be forseen (typically 100 lux with white fluorescent lamps) for safety reasons. Local safety regulations must always be considered (e.g. door locks for electrical room).
Safety aspects
8.5
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DN 65
8.6
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Sealing module
Removable layers to adapt the sealing module to the cable diameter Conductive foil
Frame
Compression wedge
Sealing module
Figure 8-6
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Feeding transformer or busbar
Armor Shield
16 mm2< A < 50 mm2 (Cu)
Figure 8-7
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Feeding transformer
Equipotential bonding
Shield
Armor
16 mm2< A < 50 mm2 (Cu)
Figure 8-8
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8.6.4 Connecting motor to INU
ACS 6000 INU
TEU
Equipotential bonding
Armor
16 mm2< A < 50 mm2 (Cu) 16 mm2< A < 50 mm2
Shield
(Cu)
Motor
Motor
8.7
Equipment grounding
The grounding cable must be connected to the grounding busbar (marked PE, Protective Earth) of the converter at only one point: at the busbar inside the TEU closest to the CBU. The connection must be in compliance with local regulations.
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8.8
a c e
b d f
Sealing inserts
CS F 16 frame
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The cable entry plate is furnished with a Roxtec frame, type CS F 16, which holds the sealing modules. These can be selected individually depending on the number, type and diameter of the cables. The frame has an integrated compression gasget and for this reason needs no separate compression wedge for keeping the cables in place. Information on dimensions and exact location is stated on the project specific layout drawing. Sealing module "a" in Figure 8-11 is part of the delivery.
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Chapter 9 - Ordering information
9.1 General
Ths chapter provides assistance in selecting the appropriate drive and the included options. Links to other documents Summary of references to linked documents in this chapter: Appendix - Technical data ACS 6000 Type code (3BHS128455 ZAB E01)
9.2
Drive selection
Specifications
The basic drive configuration and dimensioning is done by ABB sales based on the customers specification of the application and by using specialized configuration tools. The following specifications must be completed by the customer in order to provide the required application data: See Chapter 7 - Engineering information for further requirements and information.
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Select the type of rectifier (ARU or LSU) based on process needs and braking capability requirements. Add a RBU or BCU to an ACS 6000 with LSU if emergency braking capabilities are required. Select options if needed. The available options are listed in Chapter 10 - Options.
5. 6. 7.
Using the configuration rules for the ACS 6000, several rectifier and inverter units can be connected to the same common DC bus to supply big motors or more than one motor. The following rules apply: Number of ARUs + INUs 7 Total number of motors if supplied by ARU 4 Total number of motors if supplied by LSU 5 Number of ARUs 3 Number of LSUs 4 Combinations of ARU and LSU are not allowed
Note that these are only the most important rules. For a detailed list refer to the ACS 6000 Type code (3BHS128455 ZAB E01). The alignment of the converter units within a line-up is predefined.
9.3
Type code
See ACS 6000 Type code (3BHS128455 ZAB E01)
9.4
Option list
See Chapter 10 - Options.
9.5
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9.6 Technical data
See Appendix - Technical data.
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Chapter 10 - Options
10.1 Converter hardware
Process I/Os Standardized hardwired motor and transformer monitoring For details, see Standard and Optional I/O Configuration (3BHS123187 ZAB E01). Customer specific hardwired I/Os For details, see Standard and Optional I/O Configuration (3BHS123187 ZAB E01). Connection to process control For details, see Chapter 6 - Control system and process interfaces, 6.4 Fieldbus interfaces. AC disconnectors Motor operated disconnector and grounding switches on the motor side: Grounding switch (1 in Figure 10-1) Disconnector (2 in Figure 10-1) Disconnector with grounding switch for motor (4 in Figure 10-1) Disconnector with grounding switch for converter (3 in Figure 10-1)
Figure 10-1 Output switch types Cabinets Cable entry from top (power and/or control cables) (11 MVA cont. power, cable entry only from bottom)
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Water connection from top Cable transits (ROX - cable transits) ROX cable transit frames are a standard feature. Higher IP rating (IP 44, IP 54) Non-standard cabinet color Language of warning labels Customer specific labels Insulation monitoring device for medium voltage circuit Pulse encoder interface (NTAC board) for rotor speed measurement Fast I/Os (NBIO-21) Extended altitude range up to 4500 m above sea level (requires output power derating) Extended cooling water temperature range (10 C...36 C) Extended ambient temperature range (5 C...45 C) Heating cables (approx. 100 W/m) Nickel-coated busbars Varnished circuit boards
Instrumentation
Ambient conditions
Figure 10-2 Leakage sensor Raw water valve (external to water cooling unit)
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Raw water filter (external to water cooling unit) Monitoring of external water temperature
Chapter 10 - Options
The feature enables monitoring of the water temperature of the external cooling circuit. The voltage or current signal from a temperature monitoring device is connected to an anlog input module inside the WCU. When the signal increases above a parameter adjustable limit value, an alarm message is issued by the converter. Heat exchanger plates made of titanium Water cooling unit without heat exchanger for applications with fin fan cooler or chiller Deionized / distilled water for pure water circuit Glycol in deionized water (requires output power derating) Glycol in raw water (requires output power derating) High raw water pressure (10...16 bar) Flexible raw water connection
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Monitoring actual signal values Viewing and changing parameters Fault logger Event logger Data logger for fast and accurate measurements Drive control Backup and restore Communication between the ACS 6000 and the PC is achieved via fiber optic cables and PCMCIA card.
Figure 10-3 Typical DriveWindow display DriveMonitor DriveMonitorTM is an option enabling real-time access to the diagnostic data of the ACS 6000. DriveMonitorTM allows monitoring of up to 9 drives and provides an Ethernet port to an external PC, to the Intranet of the customer or the Internet. The Internet connection enables ABB service engineers to monitor the performance of the drive without being on site. The hardware consists mainly of a door-mounted optional touchscreen and a PC for data acquisition, storage and processing. The standard solution is a stand-alone PC, not mounted in the converter cabinet. Optionally, the DriveMonitorTM can be installed in a console and equipped with a monitor as shown in Figure 10-4.
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Chapter 10 - Options
DriveMonitorTM provides the following functions: Acquisition of all available drive data thus ensuring that no data will be lost in the event of a drive failure Fault and alarm notification with causes and hints for rectification Automatic reporting on predefined templates Automatic recording of parameter changes Tracking of operational conditions Long-term data logging for monitoring of component lifetime Remote diagnostics according to the service and support-line contracts See DriveMonitorTM User and Commissioning Manual for further details on DriveMonitorTM.
DriveMonitorTM Embedded PC Figure 10-4 ACS 6000 with DriveMonitorTM installed in a console
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Drive OPC A suite with SW modules for building customized PC applications with signal exchange between PC and drive system, e.g. production planning and statistics, preventive maintenance planning and others. DDCS branching unit for DriveWindow to access all AMC controllers from one location Service contracts
10.5.2 I/O with option CIW2 and CIW3 (project specific SW)
The options CIW2 and CIW3 include the same number and type of S800 I/O modules as option CIW1 and additionally a programmable AC 80 / AC 800 controller. Unlike option CIW2, the software programming is included in option CIW3. Furthermore, it is possible to replace the five I/O modules by other S800 modules and allocate the I/Os to specific functions depending on the users needs. Refer to Standard and Optional I/O Configuration (3BHS123187 ZAB E01).
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AMC controller
CH 7
Chapter 10 - Options
CH 4
DDCS
DDCS S800 Module Bus TB 820 S800 Module Bus DI 810 DO 810 DI 810 TB 820 DI 810 DO 820 AI 820
AC 80 / AC 800 Controller
DO 820
COU1
WCU
CIW2 / CIW3
Marine-type door handles Damping mat between base frame and converter cabinets Figure 10-6 Marine version
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Door arresters All doors are equipped with door arresters. When a door is opened, the door arrester engages and holds the door in the open position.
Figure 10-7 Door arrester Roof fixings ACS 6000 converters for marine applications are supplied with roof attachments for fastening the converter to the ceiling or the back wall of the drive room. The roof attachments prevent tilting of the converter (see Figure 10-8) and serve as vibration dampers. The number of roof attachments per drive depends on the length of the line-up. The roof attachments are assembled on site.
45
45 90
Ceiling fastening
Wall fastening
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Chapter 10 - Options
Figure 10-9 Roof connecting pieces Heating cables Extended range for cooling water and ambient temperature Varnished circuit boards Leakage sensor in WCU
10.8 Training
Operation and maintenance training Training on operation, maintenance and troubleshooting (including replacement of circuit boards, phase modules and semiconductors) of the ACS 6000 converter. Commissioning and maintenance training Same as above but extended by commissioning.
10.9 Testing
Additional non-standard tests Customer witness test Additional external tests Production supervision
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10.10 Documentation
Paper copies of the users manual (users manual on CD-ROM is standard)
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Index
A
Active Rectifier Unit ARU Application Control 74 42 mine hoist Motor Control Functions Motor Requirements Multi machine drive multiple units 35 41 126 25 25
B
basic configuration Bus Bars 23 64
O
Operating System Oscillation Damping overland conveyors 123 41 36
C
Cabinet Design Control Features (DTC) Control System Crowbar Thyristors 62 41 103 72, 74
P
power range Protection Functions 15 49
D
di/dt choke Direct Torque control, methods drilling rig 72, 74 39 27
R
Rolling Mill Applications Rougher mill 30 32
F
Four-quadrant operation 20
S
sendzimir mill single machine configuration Single machine drives Speed Control 34 17 24 41
G
Grounding 64
T
Torque Control 41
I
Inverter Unit INU 78
V
Voltage Limiting Unit 97, 99, 101
L
Line Supply Unit Load Share Control 70 42
M
Main Circuit Breaker Main circuit breaker, selection Main State Machine 42 125 124
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ABB Switzerland Ltd Medium Voltage Drives CH-5300 Turgi / Switzerland Tel +41 58 589 27 95 Fax +41 58 589 29 84 Email mvdrives@ch.abb.com www.abb.com/motors&drives 3BHS123322 ZAB E01 Rev. D 18-09-2009
ABB Switzerland Ltd reserves all rights to this document. Unauthorised duplication is not permitted.
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Appendix A -Technical data
Converter output / Motor connection
Table A-1 Output voltage and current ratings
Type ACx ... _1y7 ACx ... _1y9 ACx ... _2y7 ACx ... _2y9 Rated output voltage with ARU 3150 ... 3300 V 3150 ... 3300 V 2 x 3150 ... 3300 V 2 x 3150 ... 3300 V Rated output voltage with LSU with 2 x 1725 V input voltage 3000 ... 3100 V 3000 ... 3100 V 2 x 3000 ... 3100 V 2 x 3000 ... 3100 V Rated output voltage with LSU with 2 x 1650 V input voltage 3000 V 3000 V 2 x 3000 V 2 x 3000 V Rated output current 1300 A 1670 A 2 x 1300 A 2 x 1670 A
"x" stands for S (single-motor drive), M (multi-motor drive), R (redundant 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 synchronous motors with brushless excitation
Output frequency range Minimal base frequency Maximum field weakening range Maximum motor cable length Efficiency Static speed inaccuracy Dynamic speed inaccuracy Air gap torque ripple components
0...75 Hz 3.1 Hz 1:5 300 m (984 ft), longer on request Depends on individual configuration With encoder: within +/- 0.01% Without encoder: within +/- 0.1% With encoder: within 0.2 ... 0.5% s Without encoder: within 0.5 ... 1% s < 1% (Motor fn <25 Hz, frequency components below 100 Hz) < 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 Power factor for asynchronous motors
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"x" stands for S (single-motor drive), M (multi-motor drive), R (redundant drive) and T (twin drive) "..." stands for several digits of the type code (see type code sheet) "y" stands for asynchronous motors, synchronous motors and synchronous motors with brushless excitation
Safe operation with reduced output power is possible down to -20% for 3160 V input voltage. Phase shift between transformer secondary windings: 30 for 12-pulse ARUs 20 for 18-pulse ARUs
50 / 60 Hz 5% max. 2% (Uneg / Upos according to IEC 61000-2-4) Controlled to cos = 1.0 Optionally, cos can be controlled in a range of 0.8 (leading) ... 0.8 (lagging). (MVA ratings remain the same as for cos = 1.0)
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ACS 6000 with Line Supply Unit (LSU)
Table A-3 Input voltage and current ratings
Type ACx 6107_D06_... ACx 6107_L12_... Input voltage 1 x 3300 VAC, +10/-10% 1 x 2 x 1725 VAC, +10/-10% 1 x 2 x 1650 VAC, +15/-5% ACx 6109_L12_... 1 x 2 x 1725 VAC, +10/-10% 1 x 2 x 1650 VAC, +15/-5% ACx 6114_L12_... 1 x 2 x 1725 VAC, +10/-10% 1 x 2 x 1650 VAC, +15/-5% ACx 6207_L24_... 2 x 2 x 1725 VAC, +10/-10% 2 x 2 x 1650 VAC, +15/-5% ACx 6209_L24_... 2 x 2 x 1725 VAC, +10/-10% 2 x 2 x 1650 VAC, +15/-5% ACx 6214_L24_... 2 x 2 x 1725 VAC, +10/-10% 2 x 2 x 1650 VAC, +15/-5%
Rated input current 1 x 1300 A 1 x 2 x 1300 A 1 x 2 x 1300 A 1 x 2 x 1670 A 1 x 2 x 1670 A 1 x 2 x 2600 A 1 x 2 x 2600 A 2 x 2 x 1300 A 2 x 2 x 1300 A 2 x 2 x 1670 A 2 x 2 x 1670 A 2 x 2 x 2600 A 2 x 2 x 2600 A
pulses 6-pulse 12-pulse 12-pulse 12-pulse 12-pulse 12-pulse 12-pulse 24-pulse 24-pulse 24-pulse 24-pulse 24-pulse 24-pulse
"x" stands for S (single-motor drive), M (multi-motor drive), R (redundant drive) and T (twin drive) "..." stands for several digits of the type code (see type code sheet) "y" stands for asynchronous motors, synchronous motors and synchronous motors with brushless excitation
Phase shift
Phase shift between transformer secondary windings: 30 for 12-pulse LSUs 15 for 24-pulse LSUs
Input frequencies Voltage unbalance Fundamental power factor Maximum cable length
50 / 60 Hz 2% max. 2% (Uneg / Upos according to IEC 61000-2-4) cos > 0.95 300 m (984 ft)
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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 supply
Auxiliary voltage
50 / 60 Hz, +/-2% 110 VDC 220 VDC 110 VAC, 1-phase 230 VAC, 1-phase
EXU supply
Auxiliary voltage Auxiliary voltage frequency 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
50 / 60 Hz, +/-2%
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Storage, Transportation and Operation
Storage
Storage conditions
The storage conditions are based on IEC 60721-3-1 'Classification of groups of environmental parameters and their severities; Storage'.
Parameter 1K4 Climatic conditions Air temperature Relative humidity Absolute humidity 1Z3 Special Climatic Conditions Movement of surround. air 1B1 Biological conditions Flora Fauna 1M 3 Mechanical conditions Vibration: displacement amplitude 3 mm ( 0.12 in.) - (2...9 Hz) Marine application1: 1 mm (0.04 in.) - (5...13.2 Hz) 10 m/s2 - (9...200 Hz) Marine application1: 7 m/s2 (23 ft/s2) - (13.2...100 Hz) negligible negligible 30 m/s (98 ft/s) -25... +55 C (-13 F... 131F) 5...100 % 0.5...29 % Limits
acceleration amplitude
1 Requirement of classification societies: American Bureau of Shipping, Bureau Veritas, Det Norske Veritas, Germanischer Lloyd, Lloyds register
Storage time
Transportation
Transportation conditions The transportation conditions are based on IEC 60721-3-2 'Classification of groups of environmental parameters and their severities; Transportation'
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Parameter 2K4 Climatic conditions Low air temperature High air temperature: unventilated enclosures ventilated enclosures/outdoor Relative humidity Absolute humidity 2B1 Biological conditions Flora Fauna 2M1 Mechanical conditions Stationary vibration sinosoidal: displacement amplitude acceleration amplitude no no 70 C (158 F) 40 C (104 F) 95 % 60 % -40 C (-40 F)
Limits
3.5 mm (0.14 in) - (2...9 Hz) 10 m/s2 (33 ft/s2) - (9...200 Hz) 15 m/s2 (49 ft/s2) - (200...500 Hz) Marine application1: 15 m/s2 (49 ft/s2) - (9...200 Hz)
Stationary vibration random: acceleration spectral density 1m2/s3 (3.3 ft2/s3) - (10...200 Hz) 0.3 m2/s3 (0.98 ft2/s3) - (200...2000 Hz) Non-stationary vibration (incl. shock): shock response spectrum Free fall Toppling Rolling, pitching2: degree period Steady-state acceleration no no 20 m/s2 (66 ft/s2) 100 m/s2 (328 ft/s2) 0.1 m (0.33 ft) - (mass > 100 kg [220 lb]) no (mass > 100 kg [220 lb])
1 Requirement of classification societies: American Bureau of Shipping, Bureau Veritas, Det Norske Veritas, Germanischer Lloyd, Lloyds register 2 An angle of 35 (pitching) can only occur temporarily, angles up to 22.5 (rolling) can occur for long periods of time.
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Max. transport time Two months
Operation
Operation conditions Operation conditions are according to IEC 721-3-3 Stationary use at weather-protected locations.
Parameter 3K3 Climatic conditions Air temperature* 5...40 C (41...104 F) Marine application: 5...45 C (41...113 F) Temperature may drop temporarily below 0 C (32 F) 5...85 % 1...25 g/m3 (0.036 lb/in3) no Limits
Relative humidity Absolute humidity Condensation 3B1 Biological conditions Flora Fauna 3C2 Chemically active substances Sea salt and road salts Sulphur dioxide Hydrogen sulphide Chlorine Hydrogen chloride Hydrogen fluoride Ammonia Ozone Nitrogen oxides 3S2 Mechanically active substances Sand Dust (suspension)
no no
Salt mist 0.3...1.0 mg/m3 (1.084x10-11... 3.613 x10-11lb/in3) 0.1...0.5 mg/m3 (3.613x10-12... 1.806x10-11lb/in3) 0.1...0.3 mg/m3 (3.613x10-12... 1.0838x10-11lb/in3) 0.1...0.5 mg/m3 (3.613x10-12... 1.806x10-11lb/in3) 0.01...0.03 mg/m3 (3.613x10-13...1.0834x10-12lb/in3) 1...3 mg/m3 (3.613x10-11...1.084x10-10) 0.05...0.1 mg/m3 (1.806x10-12...3.613x10-12) 0.5...1.0 mg/m3 (1.806x10-1...3.613 x10-11lb/in3)
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Parameter Dust (sedimentation) 3M3 Mecanical conditions Stationary vibration sinosoidal: displacement amplitude 1.5 mm (0.06 in) - (2...9 Hz) Marine application: 1.0 mm (0.04 in) - (5...13.2 Hz) 5 m/s2 (16.4 ft/s2) - (9...200 Hz) Marine application**: 7 m/s2 (23 ft/s2) - (13.2...100 Hz) Limits 1.5 mg/m3 (5.419x10-11)
acceleration amplitude
Non-stationary vibration (incl. shock): shock response spectrum 40 m/s2 (131.2 ft/s2)
* Lower temperatures are permitted, as long as it is guaranteed that the cooling water cannot freeze (to be specified by ABB for each drive). ** Requirement of classification societies: American Bureau of Shipping, Bureau Veritas, Det Norske Veritas, Germanischer Lloyd, Lloyds register
Up to 22.5 0...2000 m (6562 ft) - with rated drive power Above 2000 m (6562 ft) to 5000 m (16404 ft) - with reduced drive power (please contact ABB)
< 75 dB (A)
Frostproofing
Lowest permitted freezing point: -25C (-13F) Permitted anti-freeze: pure monoethylene glycol Water glycol concentration for the desired frostproofing:
C 0 -10 -20 -30 -40 -50 -60 0 10 20 30 40 50 60 70 80 90 100 % volume
Frost proofing - 10 C (14 F) - 20 C (-4 F) - 30 C (-22 F) - 40 C (-40 F) Glycol 20 % 34 % 44 % 52 % Distilled Water 80 % 66 % 56 % 48 %
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Cooling
Cooling method Raw water quality Water-cooled closed loop system
Raw water of good quality is essentially industrial waterand must meet the following requirements:
Parameter pH Specific conductivity Hardness Chloride (Cl) Total dissolved salt Undissolved particles Total M-alkalinity (TAC) 79 < 500 S/cm 3 15 dH < 300 mg/l < 1000 mg/l < 1000 mg/l 0 300 mg CaCO3/l Value
- 90 F)
- 99 F) - 108 F)
Marine applications
* Nominal values; values vary depending on application ** Lower temperatures are permitted, as long as it is guaranteed that the cooling water cannot freeze.
The raw water pipes are connected to the Water Cooling Unit (WCU) with two flanges which are part of the supply. Pipe entry is through the top or the bottom of the WCU cabinet.
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The internal main cooling circuit of the converter is operated with deionized water as specified below:
Parameter pH Specific conductivity Hardness Chloride (Cl) Copper (Cu) Total dissolved salt Undissolved particles Value 7 8.5 < 300 S/cm 3 10 dH < 300 mg/l < 0.1 mg/l < 1000 mg/l < 5 mg/l
Drinking water of good quality generally meets the requirements for makeup water and may be used. Conditioning the make-up water will result in an initial reduction of the deionizer resin capacity by about 10%. The required quantity of deionized water depends on the configuration of the drive (e.g. number of INUs, EXU). The required quantity is specified on the mechanical drawings supplied with the converter. Heat dissipation to environment Approx. 6% of the losses
Converter enclosure
Standard enclosure class Cabinet color IP32
Filter mesh
Door filter mats in converters with IP 54 are specified for filter particles with a size > 10 m.
Antifreeze
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Input filter unit
If an IFU is used, the continuous power of the ARU is derated to max. 7 MVA.
According to IEC / EN 61000-4-5: Aux-supply power-ports line-to-earth: 2 kV Aux-supply power-ports line-to-line: Signal-ports: 1 kV 1 kV
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ACS 6000 - Applicable Codes and Standards
.
EMC Standards
CISPR 11 Industrial, scientific and medical (ISM) radio-frequency equipment - Electromagnetic disturbance characteristics - Limits and methods of measurement Electromagnetic compatibility (EMC) - Part 4-2: Testing and measurement techniques - Electrostatic discharge immunity test Electromagnetic compatibility (EMC) - Part 4-3: Testing and measurement techniques - Radiated, radio-frequency, electromagnetic field immunity test Electromagnetic compatibility (EMC) - Part 4-4: Testing and measurement techniques - Electrical fast transient/burst immunity test Electromagnetic compatibility (EMC) - Part 4-5: Testing and measurement techniques - Surge immunity test Electromagnetic compatibility (EMC) - Part 4-6: Testing and measurement techniques - Immunity to conducted disturbances, induced by radiofrequency fields Electromagnetic compatibility (EMC) - Part 6-2: Generic standards Immunity for industrial environments Electromagnetic compatibility (EMC) - Part 6-4: Generic standards - Emission standard for industrial environments
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IEC / EN 61800-3 Adjustable speed electrical power drive systems - Part 3: EMC requirements and specific test methods
Environmental Standards
IEC / EN 60721-3-1 Classification of environmental conditions Part 3: Classification of groups of environmental parameters and their severities Section 1: Storage Classification of environmental conditions Part 3: Classification of groups of environmental parameters and their severities Section 2: Transport Classification of environmental conditions Part 3: Classification of groups of environmental parameters and their severities Section 3: Stationary use at weatherprotected locations
IEC / EN 60721-3-2
IEC / EN 60721-3-3
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