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Machines and ACS6000c Cycloconverter

Phase current

Copyright year ABB. All rights reserved. - 1 30/01/2004

Links to machines/cyclo training material

Machines Cyclo

principle description

System

Copyright 2003 ABB - 2 -

 BA ATEM Training - 1 After Sales.ppt 2003-04-17

Ilpo Vrel

Marine AMG & AMZ Training

 BA ATEM Training - 2 After Sales.ppt

Introduction to Synchronous Machines

Type Designation Code

AMG 0710MM06 ABB Industry Synchronous Machine
G = generator Z = motor

Standard shaft height in millimeters Designation letter for frame length Designation letter for core length
BA ATEM Training - 3 After Sales.ppt

Number of poles

Training subjects

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Presentation Generator design Propulsion motor design Bearings & lubrication units Accessories Test reports Windings AVR Maintenance Hands-on

Main Components AMG

Transformers Air Filters Stator Windings Shaft End Shield D-end Bearing Exciter Neutral Point Line Terminals Stator Core

BA ATEM Training - 5 After Sales.ppt

Fan Rotor Poles Diode Bridge Rotor Windings

Main Components AMZ

Line Terminals Neutral Point Stator Windings Exciter D-end Bearing Shaft

N-end Bearing N-end

D-end Rotor Poles Stator Core

BA ATEM Training - 6 After Sales.ppt

Diode Bridge

Stator Core and Frame

BA ATEM Training - 7 After Sales.ppt

Frame and end shields are made of fabricated steel

Stator Core
Stator core is made of punched, stacked, high-grade, low-loss silicon steel sheets. Sheet thickness is 0.5 mm and it is insulated on both sides Radial cooling ducts in the stator core ensure uniform and effective cooling of the stator Complete VPI for the stator as a single unit making it virtually maintenance free Core Radial Air Duct Pressure Plate Fixing Plate
BA ATEM Training - 8 After Sales.ppt

Support Bar

Rotor

Rotor is designed to withstand the vibration and stresses appearing up to 120 % of rated speed Critical rotational speed is at least 1.5 times the nominal speed Shaft is made of forged steel and salient poles are bolted to the rotor hub Poles are constructed of punched and stacked steel plates and provided with damper winding. Cooling and supporting of windings by aluminum profiles

BA ATEM Training - 9 After Sales.ppt

Excitation

Generators and propulsion motors are with brushless excitation Exciter rotor windings are wound with enameled wire, impregnated and shrink fitted to the shaft. Securing with a key Mounting inside the motor frame with removable inspection covers Mind tightening torques when inspecting or replacing semiconductors and rectifier bridge components Diode bridge is mounted on the exciter rotor hub that is shrink fitted on to the shaft

BA ATEM Training - 10 After Sales.ppt

Windings and Insulation

MICADUR-Compact Industry (MCI) Insulation System based on Vacuum-Pressure Impregnation (VPI) and has been used 20 years and it is well known for its high reliability. Winding insulation exceeds Class F requirements (temperature limit 155C). The complete winding and its supporting structures are vacuum pressure impregnated with epoxy resin which ensures a very robust, solid and moisture resistant insulation. Insulation voltage level is matched to converter voltage waveform VPI is used for all stators and rotors

BA ATEM Training - 11 After Sales.ppt

Terminals

The stator line terminals and neutral terminals are situated in the top box on the top of the generator Excitation transformers are installed in the terminal box The terminals for excitation and control equipment are in auxiliary terminal box
Main Terminals Voltage Transformer Neutral Point

BA ATEM Training - 12 After Sales.ppt

Differential Protection Transformers Current Transformer for Parallel Operation Short Circuit Current Transformers

Cooling

For propulsion motors the internal cooling air flow is symmetrical and separate fan motors are used For generators the internal cooling air flow is asymmetrical and fan is mounted to the rotor shaft

BA ATEM Training - 13 After Sales.ppt

Balancing and Vibration

Dynamic balancing on two planes Balancing is carried out with a half key Balancing grade G6.3 Vibration level of a fully assembled generator mounted on rigid foundation is below 2.8 mm/s (RMS) with nominal speed and excitation Max.allowed vibration level is 20 mm/s (RMS) according to ISO 8528-9 (DIN 6280 Teil 11) Reference measurement is always taken in three directions on the bearings (vertical, transversal and longitudinal)

BA ATEM Training - 14 After Sales.ppt

Bearings and Lubrication

The generator is provided with split-type sleeve bearings as standard Non-drive end bearing is insulated Bearings are spherically seated to facilitate assembling and maintenance The D-end bearing is designed to carry the loads produced by a coupling misalignment and the rotor weight

BA ATEM Training - 15 After Sales.ppt

Accessories

Winding temperature pt-100 sensors Cooling air temperature pt-100 sensors Space heaters Leakage water indicators Lubrication units (motors only)

oil flow filter indicatotors jack-up pressure

BA ATEM Training - 16 After Sales.ppt

Testing

Routine test performed on every motor Type test performed on one of a series of identical motors Special tests performed as required

BA ATEM Training - 17 After Sales.ppt

Routine tests 1. Visual inspection 2. Air gap measurement and clearance check of sleeve bearings 3. Insulation resistance measurement in cold condition 4. Winding resistance measurement 5. Checking of temperature detectors and space heaters 6. Terminal markings and direction of rotation 7. Axial play for unlocked bearing 8. Bearing run 9. Vibration measurement 10. No load point 11. Short circuit point 12. High voltage tests 13. Overspeed test for generator 14. Tests of excitation cubicle 15. Insulation resistance measurement in hot condition

Type tests 16. Moment of inertia 17. No load curve 18. Short circuit curve 19. Heat run test (temperature rise test) / IEC 34-1 + IEEE 115 20. Zero power factor test 22. Losses and efficiency

Special tests 1. Sound level measurement at no load / ISO 3744 2. Sudden short circuit test / IEC 34-4 + IEEE 115 3. Measurement of the shaft voltage 4. Wave form measurement / IEC 34-1 + IEEE 115 5. Load switching on / off test 6. Starting of the synchronous motor (locked rotor test) 7. Polarization index / IEEE 43

Recommended spares for AMG/AMZ machine

1. Safety Parts

Excitation system Rectifier bridge semiconductors Temperature sensors Bearing parts Oil lubrication unit Brushes and brush holders Tachometers and encoders Protection units Water cooler element Cooling air motor & fan Slip rings Voltage and current transformers Space heater Exciter rotor and stator Rectifier bridge Rotor pole Rotor complete Stator (wound core) Stator with frame

2. Maintenance Parts

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3. Capital Parts

Site Service

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Inspection Installation Commission Maintenance On site testing Condition monitoring Trouble shooting Upgrading and modification Recondition

Technical Support

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Documentation Drawings FAT On site testing protocols Recondition instructions Insulation laboratory Redesign Recalculation

Cycloconverter principle

ACS6000c cycloconverter

Phase current

Copyright year ABB. All rights reserved. - 1 30/01/2004

Cycloconverter
Low speed and high power frequency converter

Runs always synchronous motor (AC motor with DC excitation) Power up to 27MW Motor nominal voltage 1350V... 1570V Maximum continuous current up to 4500A(water cooled) Nominal speed of delivered motors 30220rpm Maximum speed 720rpm

Product service - 2 7.2.2003

Cycloconverter in metals
Rolling mills

Nominal power Max. load High torques

0,5...15 MW 115...300 % >1000 kNm

Roughing mills for steel and aluminium Z-mills for stainless steel Tandem Cold rolling mills Cold mills for aluminium and copper Performance and availability are most important

Product service - 3 7.2.2003

Cycloconverter in Marine with Azipod

Main propeller

Nominal power Speed

up to 20 MW 100..300rpm

In cruise vessel normally 2 or 3 main propellers Safety and redundancy are really important

Product service - 4 7.2.2003

Operation of synchronous motor

The magnetic field of the stator attracts the rotor magnet The rotor rotates until the rotor N-pole meets the S-pole of stator Continuous rotation is not possible with permanent magnet

Product service - 5 7.2.2003

Operation of synchronous motor

Stator magnetic field

Battery voltage makes current Current induce field Attracts rotor magnet Stator magnetic polarity swap Rotor turns 180 Continuous rotor rotation is possible thought starting may be difficult from certain positions Jumpy torque

N S

+ _

Battery voltage polarity reversing

+ _
N S

Right timing of U swaps

Product service - 6 7.2.2003

Operation of synchronous motor

Stator

In order to allow starting in any position a stator with 3 phase winding is used A phase winding is divided in two parts opposite side of stator
Rotor permanent magnet is also replaced with winding

Excitation

Product service - 7 7.2.2003

Operation of synchronous motor

DC pulse control(simple method)

Torque is not smooth Step operation(stepper motor)

AC sinusoidal supply

Smooth torque If frequency and voltage can be controlled also motor speed can be controlled

Product service - 8 7.2.2003

 Product service - 9 7.2.2003

SM frequency vs. speed

Motor power supply

Main requirements for the power supply of motor

Sinusoidal phase currents Variable frequency and voltage Low losses (cyclo efficiency is >99,5 % at rated load) Can be easily connected to utilitys power network Fast control of currents for fast torque control

Product service - 10 7.2.2003

Cycloconverter
CONSTANT FREQUENCY AC NETWORK 50 / 60 HZ VARIABLE FREQUENCY 0...20 / 24 HZ

3 -PHASE

Product service - 11 7.2.2003

Input frequency 50 or 60 Hz + 5 % Input voltage 1000V(1000V or 1200V in marine) Output voltage controllable 01500V(01570 in marine) Output frequency controllable 0...20 / 24 Hz Auxiliary voltage 220..690VAC

Supply network
Three phase constant frequency (50 Hz or 60 Hz) constant voltage system

u u u

r time s t

20 ms (for 50 Hz) 16.7 ms (for 60 Hz)

Product service - 12 7.2.2003

1 second = 1000 milliseconds = 1000 ms

SCR thyristor
Semiconductor switch

Switches in the rectifiers have to be fast, in 50 Hz network they have to close and open 50 times every second Thus mechanical switches are unsuitable and a semiconductor switch is used instead A high power thyristor is a 0.5 mm thick and 50 - 150 mm diameter disk of silicon packed in a housing made of metal and ceramics A thyristor can withstand a voltage of over 5000 volts and conduct a current of several thousand amperes(4200 or 5200 Volts SCRs used in cycloconverter) Thyristor is controlled by a short gate current pulse of few amperes (the firing pulse)
Anode Cathode K G Gate

Product service - 13 7.2.2003

Controlled gbridge

ur us ut

=0

U output

time

Output voltage can be controller by controlling firing angle Motor current can be controlled by controlling drive output voltage

Product service - 14 7.2.2003

u+

Average voltage

 Product service - 15 7.2.2003

Firing angle

Sinusoidal output
Supply voltage

U output

I output

Product service - 16 7.2.2003

Positive and negative thyristor bridge

1

0,5

Thyristor bridge change time

I
0 90 180 270 360

-0,5

-1

Product service - 17 7.2.2003

Phase currents
Phase currents of a rolling mill cycloconverter drive, f = 8 Hz (simulation)
1.5

Phase a current
1

Phase b current

Phase c current

0.5

per unit

0 600

620

640

660

680

700

720

740

760

780

800

Time (ms)
-0.5

-1

Product service - 18 7.2.2003

-1.5

Phase voltages
Phase voltages of a rolling mill cycloconverter drive, f = 8 Hz (simulation)
1.5

Phase a voltage

Phase b voltage

Phase c voltage

0.5

per unit

0 600

620

640

660

680

700

720

740

760

780

800

Time (ms)
-0.5

-1

Product service - 19 7.2.2003

-1.5

Cycloconverter drive
Phase current

Product service - 20 7.2.2003

Excitation current (DC current)

Positive bridge

Negative bridge

Operation curves, VOLTAGE and FLUX

All electrical motors have a so called base speed or nominal speed. On AC motors it is related to frequency.
Constant flux/torque range Field weakening/ constant power range

at this speed the motor voltage is nominal(100%) below this speed excitation current is kept constant if speed is increased above this speed motor flux has to be reduced to prevent motor over voltage . Stator voltage formula is Us = * = flux, controlled by excitation current = speed This means that faster the motor is running the higher is the voltage provided that flux is kept constant At zero speed flux is nominal 100% and speed 0%, thus Us=100% * 0% = 0% At nominal speed both flux and speed are nominal, then Us=100% * 100% =100%=Nominal voltage If speed is increased over the base speed then flux(i.e.. excitation current) has to be reduced. For example 2 * base speed. Us= * = 50% * 200% = 100%

Nominal flux

Flux

Nominal voltage

Voltage

0
Product service - 21 7.2.2003

Base speed

Speed

Operation curves, TORQUE

Constant flux/torque range Field weakening/ constant power range

Motor torque is the product of flux and torque. Motor torque formula is T = * Is = flux, controlled by excitation current Is = stator current Normally all drives can produce full current through the whole speed range. Same applies also to cycloconverter. Because flux is reduced in field weakening area the absolute torque(Nm) is reduced.

Torque

Flux

Stator current

0
Product service - 22 7.2.2003

Base speed

Speed

Operation curves, POWER

Constant flux/torque range Field weakening/ constant power range

Motor shaft power is product of torque and speed. Motor power formula is P = T * T = Torque = motor speed This means that full power could be reached only at base speed.

Flux

Torque

Power Power

Speed

0
Product service - 23 7.2.2003

Base speed

Speed

Operation curves, propeller and fan

Constant flux/torque range Field weakening constant power range

Motor torque

Load curve of propeller or fan is quadratic. For example in cruise liner main propulsion field weakening point could be 125rpm and maximum speed Maximum power 145rpm.

Power Propeller load curve

0
Product service - 24 7.2.2003

125rpm 145rpm

Speed

Operation curves, rolling mill

Constant flux/torque range Field weakening constant power range

2 1

Torque 4 5 Power

Rolling mills and extrudes are constant load machines. The load depends on the rolling schedule and material. In Extruder load depends mainly on material. On the example there are roughing mill passes 15. First passes are at low speed and high torque

0
Product service - 25 7.2.2003

125rpm

Speed