ABB AC Drives SAMI MEGASTAR

Frequency converter
2.4...3.3 kV
1...10 MVA

A star in the ABB megadrive family

TE SubCom Approved 1-9-15

The world of power requires

SAMI MEGASTAR is a high SAMI MEGASTAR is the right

performance drive for induction solution for speed and torque
motors with shaft power ratings control of AC induction motors
of up to 8 MW with proven reliability.

SAMI MEGASTAR offers accurate Since 1985, ABB has delivered over
torque control and fast dynamic re- 340 MEGASTAR drives worldwide for
sponse from zero to over-synchro- such applications as
nous speeds. This guarantees high
performance for demanding applica- Fans
tions. Pumps
Extruders
SAMI MEGASTAR provides efficient Compressors
electronic speed control for large Ship Propulsion
motors, helping electricity consumers Slurry Mills
keep their energy costs down. The Rolling Mills
investment will more than pay for Traction
itself. Test Rigs

Separate reference lists for each

application are available on request.

TE SubCom Approved 1-9-15

outstanding performance

We control the motor with care

SAMI MEGASTAR has both closed

loop (vector) and open loop (scalar)
control alternatives.

A star-modulated PWM (Pulse Width

Modulation) with a three-level inverter
optimizes the motor voltage and
current and gives excellent
performance in demanding load
conditions.

All the necessary motor protection Savings and benefits All-in-one design and modular
features are included in the converter construction
control system. 99% efficiency at rated power
Near unity power factor Thanks to SAMI MEGASTAR’s all-in-
Low harmonics one design, no external reactors, or
Powerful system control with Soft starting of motors with full similar equipment, are needed. Instal-
open communication and easy torque lation, operation and maintenance
graphic programming procedures are easy to carry out.

The SAMI MEGASTAR system control Water cooling benefits The modular construction of the main
is operated by a powerful application functional parts results in several
controller (APC). It has flexible local Effective heat transfer advantages:
and remote I/O possibilities. Space saving construction
Less noise Common DC-bus multi-motor
Connection links to various PLC and No air filtering problems drives are possible with
automation systems are available. standard functional parts.
6-, 12- or 24-pulse designs are
Application programming is performed available
graphically on a PC screen. Spare-part needs are minimized
Maintenance is simplified

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 CONVERTER TYPES
SAMI MEGASTAR offers a wide
power range for large AC-drive
systems.

To select the most suitable and

economical converter drive solution,
simply contact ABB. The main data
needed for the specification is: speed
and torque requirements, supply
voltage and application type.

Type code of SAMI MEGASTAR

SAMI 2000 D 3300 Rated voltage
Type: D = standard construction
Type: DG = regenerative braking
Output power (kVA) at nominal supply voltage

Type Pulse Rated Supply Rated Shaft Dimensions Weight

number Power Voltage Current Power (W x D x H) kg
kVA V A kW mm

2000D3300 6 2000 3300 350 1600 3852x1240x2238 3500

3150D3300 6 3150 3300 550 2600 3852x1240x2238 3700
5000D3300 6 5000 3300 875 4000 4372x1240x2238 4100
6300D3300 6 6300 3300 2x550 5000 6592x1240x2238 6500
10000D3300 6 10000 3300 2x875 8000 7932x1240x2238 7700

2000D3300 12 2000 2x1650 350 1600 3852x1240x2238 3500

3150D3300 12 3150 2x1650 550 2600 3852x1240x2238 3700
5000D3300 12 5000 2x1650 875 4000 4372x1240x2238 4100
6300D3300 12 6300 2x1650 2x550 5000 6592x1240x2238 6500
10000D3300 12 10000 2x3300 2x875 8000 7932x1240x2238 7700

2000D3300 24 2000 4x1650 350 1600 4672x1240x2238 4300

3150D3300 24 3150 4x1650 550 2600 4672x1240x2238 4500
5000D3300 24 5000 4x1650 875 4000 5172x1240x2238 4900
6300D3300 24 6300 4x1650 2x550 5000 7412x1240x2238 7300
10000D3300 24 10000 4x1650 2x875 8000 7932x1240x2238 7700

2000DG3300 6 2000 3300 350 1600 4672x1240x2238 4600

3150DG3300 6 3150 3300 550 2600 4672x1240x2238 4700
5000DG3300 6 5000 3300 875 4000 5172x1240x2238 5100

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TE SubCom Approved 1-9-15
Harmonic distortion

The SAMI MEGASTAR frequency converter is supplied with

a diode rectifier connected to the mains. Especially at partial
loads, harmonic distortion caused by SAMI MEGASTAR with
a diode bridge is considerably lower than that with other
drives which have thyristor input bridges. The harmonic
current characteristics can be further improved by using 12-
pulse or 24-pulse rectifier bridges. With the 24-pulse system,
even the stringest harmonic distortion limits can be met
without costly harmonic filters.

6-pulse design

A 6-pulse bridge can be connected directly to the 3.3 kV

network without a supply transformer.

12-pulse design

The supply transformer has two secondary windings with a

30° phase shift between secondaries. This eliminates the
5th, 7th, 17th, 19th etc. harmonic frequencies. The 12-pulse
Line Supply Unit (LSU) is comprised of two 6-pulse bridges
connected in series (parallel connection in 10,000 kVA
model).

24-pulse design

The 24-pulse systems are used where the harmonic

distortion limits cannot be met with the 12-pulse system. The
supply transformer has four secondary windings with a 15°
phase shift between secondaries. This eliminates harmonics
up to the 23rd. The 24-pulse Line Supply Unit is comprised
of two 12-pulse bridges connected in parallel.

Line regenerative model

High power motor braking with energy recuperation is

achieved by using Line Regenerative Unit (LRU). Line
regenerative models of up to 5 MVA at 3300 V are available.
The maximum braking shaft power is 3.2 MW.

Regenerative braking is beneficial in applications where

frequent braking is needed, e.g. coilers in metal
applications. Single or common DC-bus drives can be used
with the Line Regenerative Unit.

The LRU is composed of a line commutated thyristor bridge

and a separate polarity changer with GTO thyristors. The
polarity changer is needed to change the operation mode of
LRU between motor and braking modes.

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 CONSTRUCTION
Thanks to the modular
construction and the common DC
bus principle, SAMI MEGASTAR
can be flexibly adapted to various
applications.

SAMI MEGASTAR is
made up of separate
mechanical and
operational units. All the
units are mounted on a
single cabinet for
powers of up to 5 MVA.
Converters with higher
ratings are divided into
two sections for
shipment.

The units are mainly

comprised of plug-in
type modules.
Maintenance and
replacement of
components is simple.

Line Supply Unit (LSU) Capacitor Bank Unit (CBU)

The rectifier bridge forms DC- interme- The SAMI MEGASTAR frequency con-
diate voltage from AC supply voltage. verter is a so-called Voltage Source
The rectifier diode bridge can be of 6-, Inverver (VSI) with constant DC-inter-
12- or 24-pulse design. The Line Sup- mediate voltage. Capacitors keep the
ply Unit (LSU) contains supply cable DC voltage constant and smooth
entry, AC fuses, input isolator and down the voltage ripple in the DC
diode bridge. circuit.

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Inverter Unit (INU)
The inverter is comprised of several motor power exceeds 4 MW. The
SAMI MEGASTAR is a GTO-thyristor plug-in type modules, which simplifies motor is then provided with double
inverter with the neutral point clamping handling and maintenance. stator windings.
(NPC) principle. The inverter Unit
forms the desired AC-supply voltage The inverter is selected on the basis of
for the motor from the three-level DC- the motor current. The single inverter
intermediate voltage. The inverter is available up to 5 MVA at the nominal
functions according to the PWM voltage 3300 V. Inverters connected in
(Pulse Width Modulation) method. parallel are used when the required

Water Cooling Unit (WCU)

SAMI MEGASTAR frequency

converter is water cooled. The plate
heat exchanger is used to transfer
heat losses from internal to external
cooling circuit. The internal closed
loop cooling circuit is filled with highly
purified water, and clean industrial
water is used in external circuit for
cooling. In cold circumstances, a
mixture of highly purified water and
glycol is used as internal cooling
liquid.

The cooling system consists of two

circulation pumps connected in
parallel (one in operation, the other as
standby), an ion exchanger unit, a
water-to-water plate heat exchanger
and a supervision unit. The cooling
system diagnostics include
temperature, conductivity and
pressure monitors. A water-to-air heat
exchanger is an option; it is installed
in the external cooling circuit.

Terminal Unit (TEU)

The Terminal Unit includes all commu- ternal communication links and I/O routed either from top or bottom.
nication and interface functions and connections and motor control pro- Auxiliary power is needed for water
system control unit. The system con- grams. circulation pumps and internal power
trol includes an Application Controller supplies for the control.
(APC) and a drive controller. The sys- Both motor cable terminals and auxil-
tem control is comprised of a drive- iary power terminals are located in
specific application program with ex- Terminal Unit. The cables can be

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TE SubCom Approved 1-9-15
 OPTIONAL FEATURES
SAMI MEGASTAR provides tailored
solutions for the most demanding
applications.

Common DC-bus drives

Several inverters can be connected to the

same DC bus. This provides flexibility in the
design of different drive configurations. The
separate inverters can operate independently
or in a master/slave connection.

A common DC-bus drive reduces the floor

space requirement and cuts down cabling
costs, because the DC-bus drive requires only
one line supply unit, one supply transformer
and a switchgear.

By-pass system

The SAMI MEGASTAR frequency converter

with a by-pass circuit offers optimum reliability
and availability. The by-pass circuit allows non-
stop production in spite of a fault situation. The
by-pass can be operated automatically or
manually.

Resistor Braking Unit (RBU)

SAMI MEGASTAR can be provided with a

Resistor Braking Unit, if rapid braking of the
drive is required. The Resistor Braking Unit
consists of water cooled resistors and a
braking chopper. It is connected to the DC bus
and is thus common to all the inverters.

The energy capacity of one RBU is 10 MWs

(max. power 1 MW) during 30 minutes. The
braking energy and power can be increased
by using units connected in parallel. The units
can be supplied without resistors, if external
resistors are preferred.

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CONTROL AND INTERFACE
The control system provides a
flexible and easy method of
controlling different drive
applications.

The SAMI MEGASTAR system control includes an Application Controller (APC)

and a drive controller. The drive controller includes a drive control program. The
drive-specific application program with external communication links and I/0
connections are located in the APC. The drive controller and the APC application
controller are connected via an optic link.

Motor control

The SAMI MEGASTAR frequency converter includes both vector control and
scalar control. The control mode can be selected by parameters inside the
software. The motor control method is selected according to the characteristics
of the application or the process.

Vector control is mainly used in applications where high dynamic accuracy is

required. The control is based on the mathematical model of a cage induction
motor. In vector control, the speed and torque of the motor can be controlled
independently over the entire speed range. The control requires a tachometer for
measuring the motor speed.

Scalar control can be used in applications where dynamic requirements are not
so significant, such as pump and fan applications. The scalar control does not
require a tachometer. In tacholess control, the motor speed is controlled by
varying the output frequency. The motor speed is settled to the value determined
by frequency and mechanical load.

Application programming

APC is a programmable application controller. The customer-specific drive

applications are carried out using functional program blocks. The application
program is created using the Windows-based programming tool Function Chart
Builder (FCB).

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 I/O connections

SAMI MEGASTAR provides flexible I/O connections. Standard hardwired

I/O connections are:

Digital inputs Digital outputs

Start Supply circuit breaker close command
Stop Supply circuit breaker open command
Emergency stop Converter ready
Supply circuit breaker status Converter running
6 spare pieces for customer Converter alarm
specific use Converter fault
2 spare pieces for customer specific use
Analogue inputs
Speed/torque reference Analogue outputs
7 spare pieces for customer Actual speed
specific use 5 spare pieces for customer specific use

The number of I/O boards can be increased on request.

One I/O board YPQ110A includes the following I/O connections:

8 digital inputs Opto-insulated inputs (1500 V)

Control voltage 24 VDC/110 VAC
Input resistance 3 kW (24 VDC), 13 kW (110 VAC)
Hardware delay 2 ms
Digital filter time 0.5 ms to 128 ms in 0.5 ms steps
8 digital outputs 6 relay outputs, normally open contacts
Max. voltage 220 VAC/VDC
Max. current 4 A at 220 VAC
Operate time <15 ms
2 opto isolated transistor outputs
Max. voltage 60 VDC
Max. current 100 mA
Operate time <0.5 ms
4 analogue inputs Differential inputs, resolution 12 bits+sign
Input voltage ±10 V or ±1 V
Input current ±20 mA or 4-20 mA
Input impedance 400 kW
Hardware filter time 5 ms
Digital filter time 5 ms to 32 s in 1 ms steps
Gain error ±0.1% (±10 V), ±0.4% (±1 V)
2 analogue outputs Output voltage ±10 V
Output current ±10 mA
Resolution 12 bits+sign
Gain error ±0.1 %

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Serial communication

The Application Controller (APC) provides a fast communication link to other

ABB drives and various automation systems. SAMI MEGASTAR can be
connected to the following communication links by means of an optional
communication board.

Board Company Protocol

YPK112A ABB AF100

YPK113A ABB SAMI PROTOCOL
SIEMENS S3964, S3964R
ALLEN BRADLEY DF1
YPK113A+1770-KF2 ALLEN BRADLEY DATA HIGHWAY
YPK114A ABB MASTER FIELD BUS
YPK117A AEG MODBUS
YPK118A SIEMENS PROFIBUS DP

Control panels and PC programs

Control panels and PC programs offer a user-friendly way to communicate with

the drive. The local control and monitoring of the drive is carried out via control
panels. PC programs offer a graphical user interface to the drive; they are an
effective commissioning and maintenance tool.

The control panels perform the following functions:

Drive operation
Operation monitoring
Diagnostics
Drive-specific parameter settings
Freely programmable pushbuttons for customer-specific purposes

The DMS (Drive Maintenance System)

is an effective DOS-based standard
tool for commissioning, maintenance
and monitoring the operation. The
diagnostic and fault logger functions
enable an effective maintenance and
fault tracing.

DDCTool is an additional Windows-

based PC program for the
commissioning and maintenance of
the drive. DDCTool can be used
instead of DMS. It has a very fast
sample time and provides a real-time
measuring system for drive
monitoring.

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 MOTORS
Reliable operation with a simple
and robust cage induction motor.

The SAMI MEGASTAR frequency converter with a

cage induction motor provides the most optimized
solution for a large AC-drive system, over a wide
power range.

The SAMI MEGASTAR drive with a cage induction

motor has the following benefits:

Simple construction without sensitive

components, such as slip rings, commutators
and brushes

No carbon dust from brushes

Robust and compact design for heavy-duty

operation

High system reliability and availability

Low installation and maintenance costs

High system efficiency

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A WIDE RANGE OF APPLICATIONS
ABB’s drive-system skills create
an optimum solution for a wide
range of industrial processes.

ABB Industry has long experience in manufacturing variable

speed drives and is the world leader in this field. The expertise
is based on long experience in the AC-drives technology and
on application knowhow of a wide range of industries.

We have supplied more than 340 SAMI MEGASTAR drives for

a number of industrial sectors throughout the world since
1985. Our customers include power plants, marine, mineral
and metallurgy industries. Our drives are used for efficient and
reliable operation of fans, pumps, ship propulsions, extruders
and other similar drive applications.

The SAMI MEGASTAR frequency converter with a cage

induction motor is a unique drive solution for highly
demanding industrial processes. It offers high availability and
reliability in harsh and hazardous environments, such as gas,
oil and mineral industries.

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 MAIN FEATURES
Type of converter Voltage source inverter VSI
Modulation principle Star-modulated PWM (Pulse Width Modulation)
Power stage GTO-thyristor inverter with neutral point clamping
Control types Vector or scalar control
Cooling method Water cooled
Construction of converter Modular based mechanics and operation
Supply voltage 2400...3300 V
Power range Up to 10,000 kVA
Line supply bridge 6, 12 or 24 pulse diode bridge
Electrodynamic braking Line regenerative and resistor braking options

TECHNICAL DATA
Supply voltage U1, 6-pulse diode bridge 3300 V ± 10%, 3-phase
Supply voltage U1, 12-pulse diode bridge 2 x 1650 V ± 10%, 3-phase, 30° phase shifts
Supply voltage U1, 24-pulse diode bridge 4 x 1650 V ± 10%, 3-phase, 15° phase shifts
Frequency f1 50 Hz or 60 Hz ± 3%
Power factor >0.95
Efficiency 99 % at rated load
Output voltage U2 0...3300 V
Output frequency f2 0...± 166 Hz
Field weakening point Adjustable 15...150 Hz
Switching frequency 330 Hz maximum
Auxiliary supply voltage 380...500 V ± 10%, 3-phase, 50/60 Hz
Auxiliary power consumption 4.5...6 kVA depending on converter type
Degree of protection IP 31 (option IP 44)
Painting RAL 7032/RAL 9011, 60 mm
Ambient temperature 0... +40 °C (option +45 °C)
Relative humidity 5...95 %, no condensation allowed
Storage temperature -40...+70 °C
External cooling water temperature 38 °C maximum
External cooling water flow rate 48...290 l/min depending on converter type
Installation site altitude Up to 1000 m above sea level
Ambient air Airborne contaminant level G1, ISA-S 71.04-1985
Standards Applicable IEC, VDE

TYPICAL CONTROL
PERFORMANCE
Vector Control Scalar control
Accuracy of speed control 0.1 % of nominal speed 0.5 % of nominal speed
Static speed accuracy 0.01 % of nominal speed 0.01 % of nominal speed
Speed dynamic accuracy 0.2 %s 3 %s
Speed step rise time 60 ms
Torque static accuracy ±3%
Torque step rise time 20 ms
Minimum frequency 0 Hz 0 Hz

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 15
TE SubCom Approved 1-9-15
The ABB group is the largest
electrical engineering
company in the world. ABB
manufactures small, medium
and high-power AC and DC
drives and positioning drives.
ABB serves a wide variety of
industries in over 140
countries.

Publ. ref. ABB MEGA 1en 9703

ABB Industry Oy We reserve the rights to changes without further notice.

Drives For more detailed information, please contact your local ABB
P.O.Box 184 representative.
FIN-00381 Helsinki
FINLAND
Tel. +358 10 222 000
Fax +358 10 222 2531

TE SubCom Approved 1-9-15