#masterdrives cuvc eng uusi dc-dc

8/10/2019 #Masterdrives CUVC Eng Uusi DC-DC

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09.01.2006 DC-AC, 4WD, Long wheel base

RTG-Training, J.Tikka

MasterDrives CUVC Frequency Converters


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SIEMENS AC-Drives

Kalmar RTG-Crane movements are done

by AC - motors.

AC - Drives are control ling motor speed

by changing supply frequency.

More frequency = more speed.

Drives are microprocessor control led

and PLC gives instructions for speed

reference according to operators input.

Speed feedback is fed to dr ive from

pulse-encoder attached to end of motors.

(Closed-loop control)

Motors are connected by shielded supply

cables to minimize any EMC noise.

Drives used are DC-AC type

(Common DC supply via Converter unit)


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SIEMENS DC - AC Drives

Main parts of Frequency Inverter:

Frequency Converter has Three (3) Main

parts.

RECTIFIER:

Rectifies Incoming AC-Power to

DC-Power. (Tyristor-/Diode Rectifier)

DC-LINK:

Smoothens recti fied DC-Power.

(Capacitor Bank)

INVERTER:

Converts DC-Power to AC-Power,

Frequency is adjustable.

CONTROL UNIT:

Controls Transistor switching and

checks that drive works properly.

(CUVC - Card, Control Unit Vector Control )

External

Rectifier DC-Link Inverter

Control Unit


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SIEMENS DC - AC Drives, Hoist Drive

+ - + - + -

Braking Units

2 x 170kW

Braking

Resistors.

3~

AC-MotorHoist

Hoist + Trol ley drive:

One drive is controll ing

one motor.

+ -

AC

toDC

Conv

erterunit

(CommonRectifier)

AC

Power

Source Ho is t

+ -

3~

AC-MotorTrolley

T r o

lle y


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SIEMENS DC - AC Drives, Gantry DS and DOS

+ - + - + -

Braking Units

2 x 170kW

Braking

Resistors.

3~

AC-Motor

Gantry Diesel Side

Gantry DS + DOS drive:

One drive is controll ing

two motors (parallel).

+ -

AC

toDC

Conv

erterunit

(CommonRectifier)

AC

Power

Source

G a ntry D

ie s e lS i d e

+ -

3~

AC-Motor

G a nt ry Di e

s e lO p p o s ite

S

id e

3~

AC-Motor

3~

AC-Motor

Gantry Diesel Opposite Side


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Block diagram of RTG (AC - AC) application (2wheel drive, short)

Gantry DOS, 75 kW

Gantry DS, 75 kW


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SIEMENS DC - AC Drives, 4WD, Acceleration

+ - + -

AC

Power

Source

+ - + -

Braking Units

2 x 170kW

BrakingResistors.

3~

AC-Motor

Ga ntry DOS

+ -

3~AC-Motor

Ga ntry DS

Acceleration:

Power Flows from supply

through AC-drive to Motor.

AC

toD

C

Converterun

it

(Com

monRectifier)

3~

AC-Motor

3~

AC-Motor


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SIEMENS DC - AC Drives, 4WD, Deceleration

+ - + -

AC

Power

Source

AC

toD

C

Converterun

it

(Com

monRectifier)

+ - + -

Braking Units

2 x 170kW

BrakingResistors.

Ga ntry DOS

+ -

Ga ntry DS

Deceleration:

When Drive is braking, motor

generates power.

Power Flows from motor through

Inverter to DC-LINK.

Voltage raises at DC-link, until Brakingunit activates and directs excess

power to Braking Resistor.

DC-LinkVolta

ge>757VDC.

DC-LinkVoltag

eStartsraising

3~

AC-Motor

3~AC-Motor

3~

AC-Motor

3~

AC-Motor

When DC-Link Voltage is

over 757 VDC, Braking Unit

Transistors open and Power

flows to Braking Resistors.


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EMC stands for "Electromagnetic Compatibili ty"

and, in accordance with the EMC Law 2(7),

it defines " the capability of a unit to operate

satisfactorily in an electromagnetic environment,

without itself causing electromagneticdisturbances which would be unacceptable for

other electrical units in this environment" .

In principle, this means that units should not

interfere with each other.

A shielded motor cable with a shield connected

at both sides causes the noise current to flow

back to the frequency converter through the

shield.

Although (almost) no voltage drop arises across

impedance Z E for shielded motor cables, the

voltage drop across impedance Z N can

affect other electrical units.

EMC - limiting the noise

More details: vc332_kompend_kap03_e.pdf


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Incoming Three-phase power

Three-phase power

Drives need power to rotate the motor.

(Comes from Diesel Generator unit )

Power is considered single-phase when it is operated

by one voltage source.

Single-phase power is used for small electrical

demands such as found in the home.

Three-phase power is produced by an alternating

current power supply system equivalent to three

voltage sources.

Three-phase power is a continuous series of three

overlapping AC voltages.

Each voltage wave represents a phase and is offset by

120 electrical degrees.

Three-phase power is used where a large quantity of

electrical power is required, such as commercial and

industrial applications.


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Incoming AC-Voltage supply is rectified to DC-

Voltage by Thyristor rectif ier unit.

DC link has capacitor bank, which smoothens

rectif ied DC Voltage.

DC Voltage is then switched to pulses by IGBTTransistors.

Transistor Inverter stage is giving positive and

negative pulses, that simulate AC voltage.

Each phase needs therefore 2 transistors

(total 6pcs.).

Pulses are PWM modulated (pulse width modulation)

This modulation gives short pulse in beginning of

cycle and longer pulse on middle of cycle, end of

cycle is also short pulse.

Output Voltage is related to area of pulses.

Short (Narrow) pulse -> low Voltage

Long (Wide) pulse -> higher Voltage

Switching frequency between positive and negative

pulses change output frequency.

DC - AC Drive, mode of operation


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These samples show you how pulses

are made with the Transistor inverter.

Notice that Voltage Increases when

pulses are wider!

When running motor on small speeds

= low frequency, pulses are also given

to both positive and negative cycles to

ensure slow Voltage change.

AC - Drive, PWM - Pulse Width Modulation


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Magnetism, Magnetic Flux

Coils in AC-motor are

generating a magnetic field.

Sinusoidal supply changes

magnetic field which is alsocalled as a flux.

Magnetic flux increases when

Voltage level raises.

Magnetic polarity changesaccording Sinusoidal Voltage

polarity.


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A rotating magnetic field must be developed in the stator of

an AC motor in order to produce mechanical rotation of the

rotor.Wire is coiled into loops and placed in slots in the

motor housing.

These loops of wire are referred to as the stator windings.

The fol lowing drawing i llustrates a three- phase stator.

Phase windings (A, B, and C) are placed 120apart.In this example, a second set of three-phase windings is

installed.

The number of poles is determined by how many

times a phase winding appears. In this example, each

phase winding appears two t imes.This is a two-pole stator.

If each phase winding appeared four times it would be a

four-pole stator.

Developing a Rotating Magnetic Field


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Magnetic Field

When AC voltage is applied to the stator,

current flows through the windings.

The magnetic f ield developed in a

phase winding depends on the direction ofcurrent flow through that winding.

The following chart is used here for

explanation only.

It assumes that a positive current flow in the

A1, B1 and C1 windings result in a north pole.


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Magnetic Field

It is easier to visualize a magnetic field i f a

time is picked when no current is flowing

through one phase.

In the illustration, for example, a time hasbeen selected during which phase A has no

current flow, phase B has current flow in a

negative direction and phase C has current

flow in a posit ive direction.

Based on the earlier chart, B1 and C2 are

south poles and B2 and C1 are north poles.

Magnetic l ines of f lux leave the B2 north

pole and enter the nearest south pole, C2.

Magnetic lines of f lux also leave the C1

north pole and enter the nearest south pole,

B1.A magnetic field results indicated by the

arrow.


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If the field is evaluated at 60

intervals from the starting point,

at point 1, it can be seen that

the field will rotate 60.

At point 1 phase C has no

current flow, phase A has

current flow in a positivedirection and phase B has

current flow in a negative

direction.

Following the same logic as

used for the starting point,

windings A1 and B2 are north

poles and windings A2and B1 are south poles.

At the end of six such in tervals

the magnetic field will

have rotated one full revolution

or 360.

Magnetic Field in Rotation


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Magnetic Field:

The amount of flux l ines (Fi) the magnetic field produces is

proport ional to the voltage (E) divided by the frequency (F).

Increasing the supply voltage increases the flux of themagnetic field. Decreasing the frequency increases the flux.

Magnetic Field and Synchronous speed (magnetic field)

Synchronous speed:

The speed of the rotating magnetic f ield is referredto as synchronous speed (NS ). Synchronous

speed is equal to 120 times the frequency (F),

divided by the number of poles (P).

If the applied frequency of the two-pole stator

used in the previous example is 60 hertz,

synchronous speed is 3600 RPM.


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C/L+ and D/L- = Incoming Supply (DC)

ZK = Capacitor bank

WR = IGBT Transistors (DC -> AC)

U2, V2 and W2 = Outgoing Supply (AC)

PSU = Power Supply Unit

IVI = Inverter Value Interface

ABO = Adapter Board

IGD = IGBT Gate Driver

C = Temperature Sensing

CUVC = Control Unit Vector Control

PMU = ParaMeterization Unit

OP1S = Operation Panel

CBP2 = Communication Board Profibus

SIEMENS DC - AC Drive, Block Diagram

W2

V2

U2

ZK

PSU

IVI

OP1S

LAPTOPPMUCBP2

CABO


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SIEMENS DC - AC Drive, Supply fuses

Supply fuses are located on top of

Inverter dr ive.

----------------------------------------------------------

Balancing Resistor is balancing the

charge of the serial connected

capacitors to prevent uneven charge of

capacitors.

(uneven charge can cause damage for

capacitors)


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SIEMENS DC - AC Drive, Capacitor bank

1L+ 1L-

Capacitor bank (Battery) is used for

smoothen the rectified DC-Voltage and

acting as quick resource of sudden

current peaks.

Balancing Resistor is balancing the

charge of the serial connected

capacitors to prevent uneven charge of

capacitors.

(uneven charge can cause damage forcapacitors)


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1

1

1

1

1

X 18X 9

X 258

X 250 X 70

5

16 3

6

13

SIEMENS DC - AC Drive, PSU - Card

X 9 = External 24 V DC supply

X 18 = Power supply from incoming

Phases U1 and V1,

+ Cooling Fan Supply

X 70 = Power supply from DC-link

X 250 = Power supply for IGD-Card

(Only in bigger drives >250kW)

X 258 = Power supply to IVI card

F1, F2 = Fan supply Fuses

POWER SUPPLY UNIT

F1 F2

Power Supply Unit:

- Provides power supply for all cards

- Powered by: - external 24 V DC supply

- Supply from incoming AC power

- Supply from DC link


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6

X 31

1

SIEMENS DC - AC Drive, IVI - Card

X 31 = Temperature sensor ( 5V=20 )

X 33 = Jumper for 3 CTs on HOIST

(Current transformers)

X 41 = Output Current measurement

(From Current transformers)

X 43 = Multiparallel Connection

(No Connection)

X 201 = ABO Connector

X 204 = Power supply for bigger CTs

(No Connection)

X 205 = IGD Control (Flat cable)

X 206 = Shunt connect ion -> PCC Card

X 208 = Power Supply from PSU

**********************************************************************************

IGD Control for Bigger Drives >200kW

U 11,12 = Firing signals for 1stphase IGBT

U 21,22 = Firing signals for 2ndphase IGBT

U 31,32 = Firing signals for 3rdphase IGBT

U 13,23,33= Feedback Signal from IGD card

INVERTER VALUE

INTERFACE

3

X 206

18

X 43

12

X 33

1 7

X 41

1

15

X 208

1 3

X 204

1

X 201

26X 205

1 13

14

1 30

U

11

U

21

U

31

U

12

U

13

U

22

U

23

U

32

U

33


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IGD-Card

Controls

IGBT- Transistor

Firing(PWM Modulation)

PWM Modulated AC ~3 phase out

DC-Link supply

1L+ 1L-

C

E

A(e)

K(c)

G

Sample picture of IGBT Transistor

SIEMENS DC - AC Drive, IGBT Transistors

IGBT = Insulated Gate Bipolar Transistor


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SIEMENS DC-AC Drive, Components

DC

-LINK

IN

(FromCommon

Rectifier)


26/35

SIEMENS AC-Drive, Semiconductors


27/35

f / Hz

60 Hz

IR

U / V

100 %

f / Hz

60 Hz

T P

100 %

TL= T/n

Voltage, Power and Torque

Voltage, Power and Torque of a squirrel Cage motor as a function of the frequency


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OP1S - Operating Panel


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P

Reset

OP1S - Operating Panel, commonly used buttons

Toggle keyis used for selecting menu levels

and switching between parameter number,

parameter index and parameter value. The

current level is displayed by the position of the

cursor on the LCD display(the command comes into effect when the key is released).

Raise keyused for increasing the displayed value

Short press = single-step increase

Long press = rapid increase(If motor potentiometer is active, this is for raising the setpoint).

Lower keyused for decreasing the displayed value

Short press = single-step decrease

Long press = rapid decrease(If motor potentiometer is active, this is for lowering the setpoint).

Reset keyused for leaving menu levels

If fault display active, this is for acknowledging

the fault (resetting).


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OP1S - Operating Panel, Controls


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PMU - Panel, Controls


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PMU - Panel, Commonly used controls

PToggle keyis used for selecting menu levels and

switching between parameter number, parameter

index and parameter value. If fault display active,

this is for acknowledging the fault (resetting).(the command comes into effect when the key is released).

Raise keyused for increasing the displayed value

Short press = single-step increase

Long press = rapid increase(If motor potentiometer is active, this is for raising the setpoint).

Lower keyused for decreasing the displayed valueShort press = single-step decrease

Long press = rapid decrease(If motor potentiometer is active, this is for lowering the setpoint).

ON keyis used for energizing the drive

(enabling motor activation).If there is a fault: For returning to fault displayI

O

OFF keyis used for de-energizing the drive by

means of OFF1, OFF2 or OFF3 (P554 to 560)

depending on parameterization.

OP1S/Laptop connection


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Single Quadrant Driving

In the speed-torque chart there are four quadrants according to direction of rotation and

direction of torque. A singlequadrant drive operates only in quadrants I or III (shaded

area). Quadrant I is forward motoring or driving (CW).

Quadrant III is reverse motoring or driving (CCW). Reverse motoring is achieved by

reversing the direction of the rotating magnetic f ield. Motor torque is developed in the

positive direction to drive the connected load at a desired speed (N).

This is simi lar to driving a car forward on a flat surface from standstill to a desired

speed.

It takes more forward or motoring torque to

accelerate the car from zero to the desired speed.

Once the car has reached the desired speed your footcan be let off the accelerator a little.

When the car comes to an incline a li ttle more gas,

controlled by the accelerator, maintains speed.

T = Torque, N = Speed


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Four-Quadrant / Dynamic Braking

The dynamics of certain loads may require four-quadrant operation.

Torque will always act to cause the rotor to run towards synchronous speed.

If the synchronous speed is suddenly reduced, negative torque is developed in

the motor. The motor acts like a generator by converting mechanical power from the

shaft into electrical power which is returned to the AC drive.

This is similar to driving a car downhill.

The cars engine wil l act as a brake.

Braking occurs in quadrants II and IV.

T = Torque, N = Speed

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