lv and mv drives 101 - abb & baldor motors & drives in ...€¦ · agenda lv and mv drives...
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LV and MV Drives 101
© ABB GroupJuly 24, 2014 | Slide 2
Speaker name: Rick Hoadley
Speaker title: Principle Consulting Applications Engineer
Medium Voltage Drives
Company name: ABB
Location: New Berlin, WI
AgendaLV and MV Drives 101
What is a VFD?§ Goals§ Motors§ Method
Line Side Requirements§ Harmonics§ Power Factor§ Ground Configurations
Motor Side Challenges§ NEMA MG-1§ Topologies§ Reflected Waves
Drive Protection§ PQ Events§ Over-Voltage§ Over-Current
This is a Non-Drive System
Fixed Freq Fixed Freq Fixed Speed
-680
680
-400
-200
0
200
400
17m 37m20m 22m 24m 26m 28m 30m 32m 34m
2DGraphSel1 VM2.V [V] 2 * L1.I [A]
Motor Side: Sinusoidal CurrentLine Side: Sinusoidal Voltage
This is a Drive System
Fixed Freq Adj Freq Adj Speed
Line Side: Current Pulses Motor Side: Voltage Pulses
-800.00
800.00
-600.00
-400.00
-200.00
0
200.00
400.00
600.00
165.00m 190.00m170.00m 172.50m 175.00m 177.50m 180.00m 182.50m 185.00m
2DGraphSel1
L1.I [A] VMab....
-800
800
-600
-400
-200
0
200
400
600
175.00m 200.00m180.00m 182.50m 185.00m 187.50m 190.00m 192.50m 195.00m
AMmu.I [A] VMmuv.V...
Why Use a VFD?
Large Operating Speed and Torque Area
0
0.5
1
1.5
2
2.5
0 300 600 900 1200 1500 1800
Torq
ue,p
u
Speed, rpm
Area of continuous operation
Area of temporary overload
DOL
Why Use a VFD?
Power Savings = Cost Savings with Fans and Pumps
0.5 to 1.5 year payback !
bypass
damper
inlet vane
VFD system
savings
Why Use a VFD?
Elimination of 6x Inrush Current for Soft Starting
Can have multiple starts per hour!
Line Current, A vs Time, s
0.0
100.0
200.0
300.0
400.0
500.0
600.0
700.0
800.0
900.0
0 5 10 15 20
I line
Line Current, A vs Time, s
0.00
100.00
200.00
300.00
400.00
500.00
600.00
700.00
800.00
900.00
0 5 10 15 20
I line
DOL Start VFD Start
Why Use a VFD?
Greater Starting Torque
Torque vs Speed0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
0 500 1000 1500 2000
T
T60
T50
T40
T30
T20
T10
T3
Why Use a VFD?
Operate at or close to Unity PF throughout Load Range
PF vs Load, %0.000
0.200
0.400
0.600
0.800
1.000
1.200
0 20 40 60 80 100
VFDDOL
Why Use a VFD?
Adjustable Torque Limit to prevent damage to equipment
No mechanical jerk, smooth acceleration
Basic AC Drive Topology6-Pulse
Fixed AC VoltageFixed AC Frequency
Adjustable AC VoltageAdjustable AC Frequency
Fixed DC Voltage
ConverterAC to DC
InverterDC to AC
DCBusFilter
AC DriveAC
MotorO
utputACLi
neIn
put
Rectifier
26
Common Power Quality Problems
§ Too High
§ Switching in PF caps
§ DC drive transients
§ Switching off inductive loads
§ Too Low
§ Voltage sags
§ Voltage notches
§ Voltage flat-topping
§ Nothing’s There
§ Voltage interruptions
41
Analysis Rules-of-Thumb
§ Rule #1 = measurements and plots
§ Don’t rely on meter measurements alone
§ Obtain waveform plots in addition to measurements
§ Rule #2 = each phase to everything else
§ Take Voltage measurements and plots each line-to-line
§ Take Voltage measurements and plots each line-to-neutral
§ Take Voltage measurements and plots neutral-to-ground
§ Take Current measurements and plots in each lineand neutral
§ Not just line-to-ground and not just line-to-line: BOTH
General Block Diagram of an Industrial AC Drive
InputFilter
Rectifier DC Filter Inverter OutputFilter
ACG
ridAC
Motor
Industrial AC Drive
What’s Unique to High Power Drives?
§ Higher Power
§ Usually major part of operation at a plant
§ Reliability is critical§ More internal monitoring
§ Greater protective features
§ Line side§ Transformer is expensive
§ Protection is critical
§ Line harmonics can be significant
§ Motor side§ Motor is expensive
§ Protection is critical
§ Reflected Waves
© ABB Inc.July 24, 2014 | Slide 43
What are Harmonics?
Rfund.V =...
0
0
40.00m
40.00m
10.00m
10.00m
20.00m
20.00m
30.00m
30.00m
-150.0 -150.0
150.0
0 0
-100.0 -100.0
-50.0 -50.0
50.0 50.0
100.0 100.0
A sinusoidal waveform has no harmonics
This is an example of a linear load
What are Harmonics?
Rtotal.V =...
0
0
40.00m
40.00m
10.00m
10.00m
20.00m
20.00m
30.00m
30.00m
-150.0 -150.0
150.0
0 0
-100.0 -100.0
-50.0 -50.0
50.0 50.0
100.0 100.0
A non-sinusoidal waveform contains harmonics
This is considered a non-linear load
Total, Fundamental, Harmonic Current
Rfund.V =...Rharm.V ...Rtotal.V =...
0
0
40.00m
40.00m
10.00m
10.00m
20.00m
20.00m
30.00m
30.00m
-150.0 -150.0
150.0
0 0
-100.0 -100.0
-50.0 -50.0
50.0 50.0
100.0 100.0
Iharm = 20AIfund = 70AItotal = 72.8AI(THD) = 28%
The differences are the harmonics
50
What are the IEEE 519-1992 standards?
Application Maximum THD (%)Special Applications - hospitals and airports 3.0%General System 5.0%Dedicated System - exclusively converter load 10.0%
Harmonic Voltage LimitsLow-Voltage Systems
Table 10.2
Table 10.3
Current distortion Limits for General Distribution Systems (120V through 69,000V)
Isc/Iload <11 11<=h<17 17<=h<23 23<=h<35 35<=h TDD (%)<20 4.0 2.0 1.5 0.6 0.3 5.020<50 7.0 3.5 2.5 1.0 0.5 8.050<100 10.0 4.5 4.0 1.5 0.7 12.0100<1000 12.0 5.5 5.0 2.0 1.0 15.0>1000 15.0 7.0 6.0 2.5 1.4 20.0Even harmonics are limited to 25% of the odd harmonic limits above
Isc=maximum short circuit current at PCCIload=maximum demand load current (fundamental frequency component) at PCC
Maximum Harmonic Current Distortion in Percent of Iload
What are the IEEE 519-1992 standards?
© ABB Inc.July 24, 2014 | Slide 51
Table 11.1
Table 10.3
Current distortion Limits for General Distribution Systems (120V through 69,000V)
Isc/Iload <11 11<=h<17 17<=h<23 23<=h<35 35<=h TDD (%)<20 4.0 2.0 1.5 0.6 0.3 5.020<50 7.0 3.5 2.5 1.0 0.5 8.050<100 10.0 4.5 4.0 1.5 0.7 12.0100<1000 12.0 5.5 5.0 2.0 1.0 15.0>1000 15.0 7.0 6.0 2.5 1.4 20.0Even harmonics are limited to 25% of the odd harmonic limits above
Isc=maximum short circuit current at PCCIload=maximum demand load current (fundamental frequency component) at PCC
Maximum Harmonic Current Distortion in Percent of Iload
Where is the PCC?
© ABB Inc.July 24, 2014 | Slide 52
For an Harmonic Study:
Need to calculate andmeasure the voltage andcurrent magnitudes anddistortion at each of the 6locations (PCCs) noted.
Need to know types ofloads, max loads andimpedances.
Need to know if there areback-up generators, too.
Basic AC Drive Topology6-Pulse Rectifier
ConverterAC to DC
InverterDC to AC
DCBusFilter
AC DriveAC
MotorO
utputACLi
neIn
put
Rectifier
Line Current Harmonic Mitigation Methods6-Pulse (120°/2 = 60°)
Basic Converter
DC Link Chokes
AC Line Reactor
Link Choke and Reactor
Passive Harmonic Filter
Passive Notch Filter
Line Current Harmonic Mitigation Methods12-Pulse (30°)
Parallel Bridges*Series Bridges
Pseudo 12-Pulse Poor-Man’s 12-Pulse
* Used in MV drives
Line Current Harmonic Mitigation Methods18-Pulse (20°)
Parallel Bridges
*Series Bridges
Auto-Transformer with Parallel Bridges
* Used in MV drives
Line Current Harmonic Mitigation Methods24-Pulse (15°), 36-Pulse (10°)
*Series or Series / Parallel Bridges, 24P
*Series / Parallel Bridges, 36P
* Used in MV drives
Line Current Harmonic Mitigation MethodsActive Front End (AFE)
AC
Line
Inpu
t
ConverterAC to DC
InverterDC to AC
DCBusFilter
Regenerative AC Drive
AC
Motor
Output
Rectifier
Line Current Harmonic Mitigation MethodsActive Front End (AFE)
AFE with Isolation Transformer *AFE with LCL Filter
NOTE: The AFE can be 2-Level, 3-Level, 5-Level
* Used in MV drives
6-Pulse: 32% Ithd 6-Pulse with 5% Line Reactor: 25% Ithd
12-Pulse: 10% Ithd 18-Pulse, AFE, AHF: 5% Ithd
The Goal of Harmonic Mitigation
Line Current Harmonic Mitigation MethodsHarmonic Content
Multi-Pulse XFMR Ithd PF
§ 6 Pulse std xfmr 30-120% 0.90
§ 12 Pulse 6 phase shift xfmr 10-15% 0.92
§ 18 Pulse 9 phase shift xfmr 5-6% 0.95
§ 24 Pulse 12 phase shift xfmr 4-5% 0.96
§ 36 Pulse 18 phase shift xfmr 3-4% 0.96
Active Front End (AFE)
§ AFE std xfmr 4-5% 1.0
Current Source PWM
§ CSI, LCI std xfmr 5-6% 0 – 1.0 lead
Power Cube
© ABB Inc.July 24, 2014 | Slide 63
HARMONICCurrent
Ireact
Ireal
Ifund
Itotal
Iharm
(in phase withline-to-neutral voltage, VLN)
REACTIVECurrent
Q
PS1
S
D
x-axis
y-axis
z-axis
REALCurrent
222 DQPS ++=
SPPF /=
Grounding Configurations
§ Floating secondary
§ Solidly grounded secondary
§ Low resistance grounded secondary
§ LV – 10, 50, 100A
§ MV – 200, 400A
Topologies
§ Reflected Wave Reduction
§ 2-Level
§ 3-Level
§ 5-Level
§ Cascaded H-Bridge
§ CSI, LCI
§ CCV
§ Matrix
Basic AC Drive Topology2-Level Inverter Topology
ConverterAC to DC
InverterDC to AC
DCBusFilter
AC DriveAC
Motor
OutputAC
Line
Inpu
t
Rectifier
The n-level VSI topology2-Level
§ 2-Level VSI
§ Phase output voltages
+VDC
-VDC
0 VDC PHNP
+VDC
NP
-VDC
VPH
The n-level VSI topology2-Level
§ 2-Level VSI
§ Phase output voltages
+VDC
-VDC
0 VDC PHNP
+VDC
NP
-VDC
VPH
The n-level VSI topology2-Level
§ 2-Level VSI
§ Phase output voltages
+VDC
NP
-VDC
VPH+VDC
-VDC
0 VDC PHNP
The n-level VSI topology2-Level
§ 2-Level VSI
§ Phase output voltages
+VDC
NP
-VDC
VPH+VDC
-VDC
0 VDC PHNP
The n-level VSI topologyH-Bridge
§ 2-Level VSI
§ Phase output voltages
A1-B1
A1-B2
A2-B2
A2-B1
B1 B2A1 0 400A2 -400 0
The n-level VSI topologyH-Bridge
§ 2-Level VSI
§ Phase output voltages
Number ofLevels, n
B1 B2A1 0 400A2 -400 0
Number of Voltagesteps, line-to-line,2n-1
2 3
-8k
8k
-6k
-4k
-2k
0
2k
4k
6k
0 34m5m 10m 15m 20m 25m 30m
2DGraphSel1
VM2.V [V] 4k * SUM3...
2-Level Waveform, Line-to-Line
2-Levels 3-Steps
The n-level VSI topology3-Level
§ 3-Level NPC VSI
§ Phase output voltages
+VDC
NP
-VDC
VPH+VDC
-VDC
0 VDC PHNP
The n-level VSI topology3-Level
§ 3-Level NPC VSI
§ Phase output voltages
+VDC
NP
-VDC
VPH+VDC
-VDC
0 VDC PHNP
The n-level VSI topology3-Level
§ 3-Level NPC VSI
§ Phase output voltages
+VDC
-VDC
0 VDC PHNP
+VDC
NP
-VDC
VPH
The n-level VSI topology3-Level
§ 3-Level NPC VSI
§ Phase output voltages
B1 B2 B3A1 0 200 400A2 -200 0 200A3 -400 -200 0
Number ofLevels, n
Number of Voltagesteps, line-to-line,2n-1
3 5
-8k
8k
-6k
-4k
-2k
0
2k
4k
6k
0 35m5m 10m 15m 20m 25m 30m
2DGraphSel1
3-Level Waveform, Line-to-Line
5-Steps3-Levels
The n-level VSI topology5-Level
§ 5-Level ANPC VSI
§ Phase output voltages
+VDC
NP
-VDC
+VDC/2
-VDC/2
VPH+VDC
-VDC
0 VDC PHNP
+VDC /2
-VDC /2
The n-level VSI topology5-Level
§ 5-Level ANPC VSI
§ Phase output voltages
+VDC
NP
-VDC
+VDC/2
-VDC/2
VPH+VDC
-VDC
0 VDC PHNP
+VDC /2
-VDC /2
The n-level VSI topology5-Level
§ 5-Level ANPC VSI
§ Phase output voltages
+VDC
NP
-VDC
+VDC/2
-VDC/2
VPH+VDC
-VDC
0 VDC PHNP
+VDC /2
-VDC /2
The n-level VSI topology5-Level
§ 5-Level ANPC VSI
§ Phase output voltages
+VDC
NP
-VDC
+VDC/2
-VDC/2
VPH+VDC
-VDC
0 VDC PHNP
+VDC /2
-VDC /2
The n-level VSI topology5-Level
§ 5-Level ANPC VSI
§ Phase output voltages
+VDC
NP
-VDC
+VDC/2
-VDC/2
VPH+VDC
-VDC
0 VDC PHNP
+VDC /2
-VDC /2
The n-level VSI topology5-Level
§ 5-Level ANPC VSI
§ Phase output voltages
+VDC
NP
-VDC
+VDC/2
-VDC/2
VPH
The n-level VSI topology5-Level
§ 5-Level ANPC VSI
§ Phase output voltages
+VDC
NP
-VDC
+VDC/2
-VDC/2
VPH
The n-level VSI topology5-Level
§ 5-Level ANPC VSI
§ Phase output voltages
+VDC
NP
-VDC
+VDC/2
-VDC/2
VPH
The n-level VSI topology5-Level
§ 5-Level ANPC VSI
§ Phase output voltages
+VDC
NP
-VDC
+VDC/2
-VDC/2
VPH
The n-level VSI topology5-Level
§ 5-Level ANPC VSI
§ Phase output voltages
+VDC
NP
-VDC
+VDC/2
-VDC/2
VPH
The n-level VSI topology5-Level
§ 5-Level ANPC VSI
§ Phase output voltages
B1 B2 B3 B4 B5A1 0 100 200 300 400A2 -100 0 100 200 300A3 -200 -100 0 100 200A4 -300 -200 -100 0 100A5 -400 -300 -200 -100 0
Number ofLevels, n
Number of Voltagesteps, line-to-line,2n-1
5 9
-8.0k
8.0k
-6.0k
-4.0k
-2.0k
0
2.0k
4.0k
6.0k
0 35m5m 10m 15m 20m 25m 30m
2DGraphSel1
5-Level Waveform, Line-to-Line
9-Steps5-Levels
How are VSI and CSI similar?
© ABB Inc.July 24, 2014 | Slide 123
Input Filter Rectifier DC Filter Inverter Output Filter
ACDC
DCAC
ACDC
DCAC
How are VSI and CSI similar?
© ABB Inc.July 24, 2014 | Slide 124
Input Filter Rectifier DC Filter Inverter Output Filter
ACDC
DCAC
ACDC
DCAC
Reflected Waves
§ Affected by:
§ Length of cable between drive and motor
§ Rate of rise of voltage (dV/dt)
§ Voltage step size
§ Pulse width
© ABB Inc.July 24, 2014 | Slide 131
short
© ABB Inc.July 24, 2014 | Slide 132
-1.00
2.50
-500.00m
0
500.00m
1.00
1.50
2.00
800.00u 1.20m900.00u 950.00u 1.00m 1.05m 1.10m 1.15m
2DGraphSel1
VM1.... C5.V ...
50 ft
longer
© ABB Inc.July 24, 2014 | Slide 133
-1.00
2.50
-500.00m
0
500.00m
1.00
1.50
2.00
800.00u 1.20m900.00u 950.00u 1.00m 1.05m 1.10m 1.15m
2DGraphSel1
VM1.... C5.V ...
500 ft
longest
© ABB Inc.July 24, 2014 | Slide 134
-1.00
2.50
-500.00m
0
500.00m
1.00
1.50
2.00
800.00u 1.20m900.00u 950.00u 1.00m 1.05m 1.10m 1.15m
2DGraphSel1
VM1.... C5.V ...
2000 ft
When does PD (Corona) occur?
• Reflected wave produces voltage peaks at the motor terminals
• Terminal voltage in excess of the insulation system CIV level willbegin the PD / CORONA process
• Excessive voltage causes partial discharges / corona that attacksinsulation materials
-3.00
3.00
-2.00
-1.00
0
1.00
2.00
500.00u 3.00m750.00u 1.00m 1.25m 1.50m 1.75m 2.00m 2.25m 2.50m 2.75m
2DGraphSel1
VM1.V [V] VM2.V [V]
DC Bus
CIV Level
CIV Level
How can we reduce the dV/dt?Filtering
Basic Inverter and Motor
*dV/dt Filter
Sinewave Filter
Output Load Reactor
*Broadband Sinewave Filter
RC Terminator
* Used in MV drives
Step size of 100%
© ABB Inc.July 24, 2014 | Slide 138
-1.00
2.50
-500.00m
0
500.00m
1.00
1.50
2.00
800.00u 1.20m900.00u 950.00u 1.00m 1.05m 1.10m 1.15m
2DGraphSel1
VM1.... C5.V ...
500 ft
Vpk is about 1.7x the Voltage step size
Step size of 20%
© ABB Inc.July 24, 2014 | Slide 139
-1.00
2.50
-500.00m
0
500.00m
1.00
1.50
2.00
800.00u 1.20m900.00u 950.00u 1.00m 1.05m 1.10m 1.15m
2DGraphSel1
VM1.... C5.V ...
500 ft
Have small voltage steps
dV/dt = 10,000 V/us
© ABB Inc.July 24, 2014 | Slide 140
500 ft
-1.00
2.50
-500.00m
0
500.00m
1.00
1.50
2.00
800.00u 1.20m900.00u 950.00u 1.00m 1.05m 1.10m 1.15m
2DGraphSel1
VM1.... C5.V ...
dV/dt = 500 V/us
© ABB Inc.July 24, 2014 | Slide 141
500 ft
-1.00
2.50
-500.00m
0
500.00m
1.00
1.50
2.00
800.00u 1.20m900.00u 950.00u 1.00m 1.05m 1.10m 1.15m
2DGraphSel1
VM1.... C5.V ...
Multi-Step Approach, low dV/dt
© ABB Inc.July 24, 2014 | Slide 142
-1.32
1.04
-1.00
-750.00m
-500.00m
-250.00m
0
250.00m
500.00m
750.00m
0 12.00m2.00m 4.00m 6.00m 8.00m 10.00m
2DGraphSel1
C5.V ...
Implementation in a MV Drive
© ABB Inc.July 24, 2014 | Slide 143
InputFilter
OutputFilter
DC BusFilterRectifier Inverter
The n-level VSI topology5-Level phase-to-phase voltage levels
0 0.005 0.01 0.015 0.02 0.025 0.03 0.035 0.04-15
-10
-5
0
5
10
15
volta
ge(k
V)
Converter phase to phase voltage
time(s)
© ABB GroupJuly 24, 2014 | Slide 148
Operation and Protection Concept
§ Try to keep operating
§ If unable to due to external issues§ Alarm, but don’t stop
§ Trip
§ If catastrophic failure§ Limit collateral damage
§ Minimal MTTR (mean time to repair)
§ Look-out for its motor and transformer, too!§ Like a big brother or sister
© ABB LV DrivesProperty of ABB LV Drives, Do Not CopySlide 149
LV Low Harmonic DrivesActive front end drives, what do they look like?
Wall-mounted low harmonicdrive ACS800-U11/U31
10 – 125 HP
Cabinet-built low harmonic driveACS800-17/37
75 - 2800 HP
© ABB LV DrivesProperty of ABB LV Drives, Do Not CopySlide 150
MV Low Harmonic DrivesActive front end drives, what do they look like?
MV DrivesACS 2000 4kV - 6.9kV
300 – 3,000 HP
ACS 6000 2.3kV, 3.3kV
4,000 – 31,000 HP
Questions?
Rick HoadleyABB, New Berlin, WI(262) [email protected]
HARMONICCurrent
Ireact
Ireal
Ifund
Itotal
Iharm
(in phase withline-to-neutral voltage, VLN)
REACTIVECurrent
Q
PS1
S
D
x-axis
y-axis
z-axis
REALCurrent
222 DQPS ++=