ABB expands power range of locally manufactured ACS 2000 medium voltage drive
2013-04-19 - ABB's 4kV general purpose medium voltage drive continues to achieve ultra low harmonic performance in a compact package for quick installation at higher power ranges
New Berlin, Wisconsin, April 19, 2013 – The ACS 2000, ABB’s active front end drive for general purpose applications, is now available with higher power capabilities, up to 3000 HP.
Developed with the latest drive technologies
The ACS 2000 is ideal for general purpose applications where a medium voltage installation is required, such as pumps, fans, blowers and conveyors. Users across many industries, including water, wastewater, power, cement, mining and HVAC, can all derive significant energy savings as well as more reliable process control while benefiting from the drive’s compact, lightweight design.
The ACS 2000’s direct-to-line connection means it’s transformerless, resulting in a small footprint for space-sensitive applications. The design is packed with innovative technology such as a high voltage IGBT based active front end and patented multi-level switching topology, providing both line and load friendly operation. The ACS 2000 design provides near sinusoidal current and voltage waveforms making the drive compatible for use with standard NEMA rated motors.
Building on success
The installed base for the ACS 2000 of both 4kV and 6kV ratings continues to expand in nearly every country in the world with the release of the third 4kV frame size. In addition to the expansion in power ratings, additional pre-engineered options such as a fused input contactor with disconnect and an auxiliary power transformer have been added to the product line.
“In working with many customers in the field, we’ve found areas to enhance our offering, such as adding a configurable disconnect that can provide a further integrated solution,” added Jeff Peterson, Central Region Sales Manager Drives and Controls. “Our scalable approach to the ACS 2000 is more than just increasing our power range, but giving customers further flexibility while leveraging a tried and true technology platform.”
Ultra Low Harmonic (ULH) design
With the integration of an Active Front End (AFE), line side harmonics are minimized without the use of expensive, specialized transformers. This ultra low harmonic (ULH) design meets the requirements for current and voltage harmonic distortion per IEEE 519 and IEC 61000-2-4 standards. With the direct-to-line configuration, the user benefits include:
- a more compact size requiring less space in the electrical room
Extremely reliable with low cost of ownership
- a lighter weight design reducing transportation cost and simplifying installation
- “three in – three out” cabling concept reducing installation time and cost
The drive is designed for high reliability, which is achieved through the use of proven, scalable technologies such as:
- the multi-level Voltage Source Inverter (VSI) topology
- high-voltage IGBT power semiconductors
- Direct Torque Control (DTC) motor control platform
- withdrawable phase modules give front access to all components for ease of maintenance
These technologies increase reliability, minimize mean time to repair (MTTR) and extend mean time between failure (MTBF), maximizing availability.
The ACS 2000’s drive control platform uses ABB’s award-winning DTC, resulting in the highest torque and speed performance as well as other unique functionalities such as power loss ride-through. Control of the drive is immediate and smooth under all conditions.
By actively managing power factor, the ACS 2000 DTL can maintain unity power factor across the entire speed range of the drive while providing valuable energy savings to the end user. In addition, the AFE enables regenerative operation which feeds back braking energy into the line supply, further reducing overall energy consumption.
The ACS 2000 medium voltage drive is a natural fit with ABB’s Baldor-Reliance medium voltage motor range. “Our motors and drives have been tested and matched in an optimally packaged solution for rotating machines and intelligent control,” offered Johan Karlsson, Managing Director of ABB’s large motor and generator business in the United States. “Very few companies can offer a singular solution that gives the customer a high quality motor-drive package from one supplier, manufacturing both products right here in the United States.”
State-of-the-art test facility to support late stage assembly
ABB's New Berlin, Wisconsin facility is the R&D, manufacturing and testing hub for the ACS 2000 serving the global 4kV market, in its newly expanded power range. The test infrastructure for the ACS 2000 includes ABB motors, transformers, switchgear, and control system architecture. "We wanted to maximize what this infrastructure could do," noted Paul Nolden, Local Product Group Manager, MV Drives US. "Automated test configurations and late stage assembly are made possible by the tremendous capability of ABB's power and automation product offering." The operational efficiency at the New Berlin facility is further improved by utilizing the regenerative capability of the ACS 2000 to feed energy back to the grid, recovering around 80 percent, drastically reducing the carbon footprint of the entire test system.