Copyright 2011, Toshiba Corporation.

Pete Pelletier, P.Eng

Sr. Sales & Solutions Engineer

Cell: 905-379-4091

Email: Pete.Pelletier@toshiba.com

Variable Frequency Drive Presentation

Outline

TOSHIBA

Corporate Overview

Global Operations

Toshiba International Corporation (TIC), based in Houston, Texas Overview.

TIC Expands INTO CANADA. Hamilton, Ontario. Product Line Focus: Contactors, Breakers, Starters, Motors, Variable Frequency Drives

VARIABLE FREQUENCY DRIVES

Toshiba VFD’s (Low & Medium Voltage)

Benefits of VFD’s

Constant Torque & Variable Torque Applications

Speed Torque Curves (ATL & w VFD’s)

Overspeed Capability

Affinity Laws for Energy Savings on VT Loads

Energy Saving Calculator

Drive Power Platform and Top Application Concerns (Harmonics, dv/dt issues, Bearing Currents)

Synchronous Transfer

Permanent Magnet Motor&Drive System (Super Efficiency System, IE4+)

Employees:

210,000 (As of March,2012)

Established: 1875

Tokyo Headquarters Net Sales

M$

Operating

Income%

Toshiba Corporation –Revenue’s

Consumer Products

Sector

5,951M$

Social

Infrastructure

Sector 26,519M$

Digital Products

Sector

14,376 M$

Electronic Device

Sector

13,261M$

22%

FY2012

Sales

61,000M$

Others

Toshiba Corporation -Sales by Segment

24%

10%

1%

43%

Toshiba Industrial Products Canada

(TIPCA)

Toshiba Int’l Corporation (TIC-HOU)

Toshiba Industrial Products

Manufacturing Corporation (TIPM)

Toshiba Industrial Products

Asia Co., Ltd. (TIPA)

Toshiba Mitsubishi-Electric Industrial

Systems Corporation (TMEIC)

Toshiba Global Operations

Toshiba Int’l Corporation (TIC-AUS)

TIPCA- Hamilton, Ontario

STD. SPECIALS RANGE TARGET MARKET

VERTICAL

(VSS & VHS)

500-10,000 HP

OIL & GAS, WATER

& WASTE WATER,

CHEMICAL,

MINING

LARGE MV

• 2500-12,000 HP

• 2 POLE UP TO 6000

HP

• STIFF SHAFT DESIGN

ON 2 POLE UP TO

4000 HP

OIL & GAS, WATER

& WASTE WATER,

CHEMICAL,

MINING

LARGE XP

350-1000 HP

OIL & GAS,

CHEMICAL,

MINING, GRAIN

APPLICATIONS

WOUND ROTOR

UP TO 8000 HP

MINING, MINERAL

PROCESSING,

CONVEYORS

SPECIAL PRODUCTS RANGE

NUCLEAR

0.5-12000HP

WATER COOLED (WATER JACKET)

75-1000HP

MILITARY SPEC

10-300HP

HI-TEMP. TUNNEL FAN

100-500HP

MM FRAME WITH OIL LUBE BEARINGS

284T – 509 FRAME

Toshiba International Corporation (TIC)

TIC Plant in Houston, Texas

NEW

6

Multiple Functional Competency

TIC-Business Line Up & Structure FY2014-15

Toshiba International Corporation

T&D Div.

<Houston>

Group Staff

<Houston>

Motor & Drive

Div.

<Houston>

Power Electronics Div.

<Houston>

AGM GM

GM

SCiB

UPS BU PV BU

Energy Solution

T&D

PAC

PV

PM

PE Plant

AGM AGM

Social Infrastructure Group <Houston>

GM

Motor BU

BUM

Motor Plant Control Plant HEV Plant PM PM APM PM

Solutions

<Houston>

ASBU

Transportation

S&A

Automation

Industrial Sales

R&D Locations Houston College Station Austin Dallas Hamilton, Ont

SCM

QS

Corporate

<Houston>

Legal

Finance HR

IT Mar Com

Strategic Planning

GP EVP

Head Count :2,116 Corporate: 125

SI Group : 1638

(As of Dec. 30 2013)

BUM VP

34

125

123 449 293 110

306 36 247 40

1638

Drive BU

FS

TIPCA MTR 34

84

68

11 24 6

Engineers

Total

People

1.5 2.5

1.1

5.6

3.8

2.9 Total 17.4M USD

Continued Product Development for Future Success.. R&D FY14 Record Year

Motor

LVD

MVD

UPS

Austin (Software)

T&D

Toshiba Starters (Vacuum Contactors & Breakers)

Breaker s

HV6:

HVK:

7.2KV, 600A

15KV, 1200, 2000, 3000A

VZ: 24KV, 630A, 2000A

Contactors

1.5KV, 600, 720A

7.2KV, 400A

7.2KV, 720A

15KV, 400A

HCV-1

HCV-5

HCV-6

CV-10

JK Starter

FVNR, FVR MV SSS, RVAT

Feeder (Latched, MV Drive)

PFCC Controller Synch By-Pass

1.5KV

7.2KV

15KV

7.2KV

15KV

24KV

JK OEM Kit

10

TEFC LVM Products (NEMA PREMIUM)

LOSSES AND METHODS OF REDUCTIONS 1) Stator I2R: Stator losses are due to the I2R heating effect of current flowing through the resistance of the stator windings.

The EQP III motor utilizes: A new stator geometry which allows for increased slot fill. Optimized magnetizing current. Turns optimized for the lowest resistance.

2) Rotor I2R: Rotor losses due to the I2R heating effect from the induced current that flows through the resistance of the rotor bars. The EQP III motor incorporates: A new rotor geometry which increases the volume of aluminum in the rotor bars. Increased end ring area to reduce resistance. Rotor bar resistance optimized to maintain design C starting torque and close to normal slip values.

3) Core Loss: Core losses consist of hysteresis losses (the energy required to magnetize the core) and eddy current losses in the stator core (magnetically induced circulating currents).

The EQP III motor employs: Extremely high grades of annealed magnetic Silicon Steel to reduce hysteresis losses. Type M36 steel is used for motors up to 320 frame and

type M22 steel is used for motors above 320 frame. Thinner laminations to reduce eddy current losses. 26 gauge steel as opposed to 24 gauge is used on the EQPIII C5 coreplating which allows burnout at up to 1000degF without damage to the core. Low flux densities through longer rotors. Enlarged air gap to reduce the rotor surface harmonic heating. Reduced rotor surface losses are accomplished through a two pass machining process which reduces the possibility of shorted rotor

laminations due to reduction of smearing caused by normal single pass machining. 4) Stray Load Loss: Stray load losses are defined as losses other than Stator I2R, Rotor I2R, Core and Mechanical. They are primarily attributed to

leakage reactance fluxes induced by load current. The EQP III motor minimizes stray losses by: Optimizing the skew of the rotor bars. Increasing the air gap to reduce harmonics. Maintaining tighter air gap tolerances. Increasing the rotor and stator length which increases cross sectional area which reduces magnetic flux density.

5) Mechanical Loss: Mechanical losses are caused by friction in the bearings and windage of the external fan and internal rotor fins. The EQP III motor utilizes: Smaller rotor fins in conjunction with the larger end rings (mentioned earlier) to reduce windage within the motor. An optimized external fan. Larger than industry standard bearings, even though smaller bearings are lower in losses, they are not used on the EQP III.

BREAKDOWN OF LOSSES Losses are grouped into five categories and typically have associated loss contributions as follows:

1) Stator I2R……………(35%) 2) Rotor I2R…………….(25%) 3) Core Loss……………(25%) 4) Stray Load Loss…….(10%) 5) Mechanical Loss…….(5%)

Performance Compromises: • Efficiency • Torque • Temperature Rise

AC INVERTER DRIVES OEM -

Micro (S15)

AS1

GX9

PlusPack (6p,12p,18p)

W7 (18p)

GX7M

GX7R

230-460V; 0.1-20HP

208-690V; 0.7-700 HP

575-690V; 5–1,200HP

400-480V, 60-1,500 HP

460V: 20-500Hp, 690V: 75-400Hp

480V, 690V, 130-1,750 Hp

480V, 30-150Hp

S15

AS1

VFD/ASD Lines (LV Voltage)

GX9

W7

Plus Pack

GX7M

GX7R

Great Local Business Strength! ‘Toshont Panel Shop’

VFD Lines (MV Voltage)

• Available from 300-11,000Hp

• Introduced in 2002

• Voltage Source Drive

• To date ~ 5000 units sold

• 2400, 3300, 4160, & 6600V Outputs

• Wide Range of Input Voltages Available up to 13.8kV

• Active Front End (Regen) Option

• Air Cooled

• Built to Maximize Personnel Safety

Worlds First Outdoor MV Drive ‘MTX’

• MTX-15 (up to 1500HP)

• MTX-30 (2000 to 3000HP)

• MTX2-60 (up to 6000HP)

• MTX2-15 (up to 1500HP) Available in Low Profile or Modular Drive Versions

Benefits of VFDs

Speed Control Energy Savings on VT loads $$$$

(Control process with changes in speed instead valves, vanes or dampers)

Controlled Acceleration & Deceleration (Minimizes Mechanical Shock)

Reverse Operation Capability

Reduced Inrush Ultimate soft starter (No Inrush, Minimize Peaks-Global Adjustment, Eliminates Voltage Sag, )

Unlimited starts per hour in most applications

Torque Advantages Excellent Torque Performance (BDT at all speeds when sized for current, Better Torque than SSS and RVAT)

Adjustable Torque Limit

Power Factor Correction Higher PF (0.98) than running motors across the line

Vector control Master follower application

Slip compensation

Over speed Can run motors faster than on utility power.

Motor braking and/or VAR compensation (Regen drive)

One drive for multiple motors (Sync/Transfer)

Constant Torque & Variable Torque Loads

• Pump loads with solids – slurry pumps

• Fan loads with heavy concentrations of dust/ solids – cyclones & separators

In Between Loads (Constant & Variable Torque)

Speed Torque Curve - 60 Hz Across The Line

1777RPM

Pullup Torque

Breakdown Torque

Breakaway Torque

Motor Current

Current inrush is typically 650% motor FLA

during start.

No speed control- only full speed

Motor Torque on Adjustable Speed Drives

900 RPM ≈ 30hz , 1800 RPM ≈ 60hz

1750RPM 850RPM

When on an ASD, motor speed torque curve will

be shifted horizontally for each additional

frequency.

Motor Current

Motor Overspeed is possible with a VFD as long as

there is available torque and current

(motor and driven equipment must be able to handle

the higher speed)

During motor overspeed condition

Speed will increase (higher ‘f’ results in higher

impedance, ‘V’ maxed at 60Hz, Torque therefore must

decrease)

On Variable Torque Loads, centrifugal load increases

exponentially with overspeed

Available torque will decrease to maintain

constant motor power.

Power = Speed x Torque

T

O

R

Q

U

E

100%

60Hz

50%

30Hz

V

O

L

T

S

FREQUENCY

0

Available Motor

Torque

V/f pattern

Motor Overspeed

Torque Begins

To Drop Off

100%

50%

0

Flow

Volume

Pressure

(Head) Power

Speed SpeedSpeed

N2

N1

2

Where: N = Fan or Pump Speed

Q = Flow (CFM)

P = Pressure (Static inches of water or feet of head)

HP = Horsepower

N2

N1

N2

N1

3

Q1

Q2

==P

1

P2

HP1

HP2

=

AFFINITY LAWS

Centrifugal Loads [Fans, Pumps (no static head), etc.]

Energy Savings

Numeric Description of the

Affinity Laws

Speed Flow Required

Power

100% 100% 100%

90% 90% 73%

80% 80% 50%

70% 70% 34%

60% 60% 22%

50% 50% 13%

40% 40% 6%

30% 30% 3%

Energy Savings

A 10 % reduction in speed reduces power consumption approximately 27%

If the speed of a fan is reduced from 60 to 54Hz a 27% savings in energy y recognized

1- (54/60)3 = 27.1%

Energy Savings Calculator & Power Consumption Estimate

Why VFD as

Opposed to Inlet

Vanes and Outlet

Dampers?

Energy Savings

Drive Power Platform and Top Application Concerns

* Fastest growing factory related non-linear load issue is with AC drives

* This is due to the ever increasing number of installations

Non-linear Commercial loads

Fluorescent lights

Computers and CRT’s

Fax machines

And other single phase office equipment

Non-linear Industrial loads

Welders

Arc furnaces

UPS and DC power supplies

DC Drives & AC Drives

Common Sources of Harmonics

Component overheating

• Distribution transformers & wires

Nuisance tripping causing lost productivity due to sensitive equipment

Equipment malfunction

Noise transfer to other loads or other utility customers

Incorrect meter readings or relay malfunctions increasing maintenance costs and/or downtime

Communication or telephone interference problems

Others

Harmonic Related Problems

Motor Bearing Currents

Some motors do not have insulated bearings and it is important to ask if the drive will elevate bearing voltage to the existing motor as this could lead to premature bearing failure.

With Toshiba’s design features associated with limiting the Neutral Shift Phenomenon, and thus common mode currents, bearing stresses and failure are not a concern.

Common Mode Currents (Bearing Currents)

One Drive With 3 Motors

APPLICATION:

COMPRESSOR

PUMP

ADVANTAGES:

STARTING DUTY

NO INRUSH CURRENT

PROCESS CONTROL WITH LAST MOTOR

FOR START / RUN DUTY – SIZE THE DRIVE CORRECTLY

Synchronous Transfer and Capture

Permanent Magnet Motor

Next Generation High Efficiency Motor Drive

Potential Markets

Refrigeration & Chillers Compressors & Fans Conveyors

Permanent Magnet Motor Control

S15 230 VAC 1 Phase

• ¼ HP to 3 HP 230/460 VAC 3 Phase

• ½ HP to 20 HP

AS1 230/460 VAC 3 Phase

• 1 HP to 60 HP, 230 VAC • 1 HP to 100 HP, 460 VAC

• v166 only

Efficiency Comparison Charts

Permanent Magnet Motor Advantages

Efficient High Precision Speed Control

Simple Maintenance Easy Replacement

Stator

Permanent Magnet

Comparing Losses between Induction Motor and Permanent Magnet Motor

Induced Current

Induction Motor

PM Motor

Iron Loss

Primary Copper

Loss

Secondary Iron Loss

Other

Iron Loss

Primary Copper

Loss

Other

Overview of Permanent Magnet Motor – Part 1

IEC Motors in Metric Frame (JIS Standard Equivalent)

IE4 Equivalent (Not yet Legislated)

No Secondary Current

No Slip

Excellent Speed Stability

Overview of Permanent Magnet Motor – Part 2

0.4 kW to 55 kW (0.5 HP to 75 HP) / 1800RPM

Frame Sizes Offered 71M to 225S

S15 Drive Compatible up to 15 kW

4 Pole (0.75 kW and below) / 6 Pole (1.5kW and above)

Rare Earth Metals

Recent Permanent Magnet Progress

• Magnet production still concentrated in China • China more aware of possibility of spoiling the market

• Major diversification of rare earth sources • US, Australia and Canada are opening mines

• Projects in Brazil, India, Russia and others

• Research programs starting to deliver • Low dysprosium rare earth magnets in use

• Grain boundary enhancement techniques

• Dysprosium-free rare earth magnets on horizon

• Anisotropic bonded magnets improving

• MagFine products to 21 MGO as processing improves

• More use of SmFeN and Cobalt compounds

• Improved ferrite magnets - grade 15 and higher

Future Permanent Magnet Improvements

• Even more research projects than 2 years ago • Japan – MagHEM, ESICMM

• US – REACT, Strategic and Critical Material Program

• Europe – REFREEPERMAG, NANOPYME, MAG-DRIVE, ROMEO, PerEMot • China, Russia, India, Brazil and others also involved

• Ongoing research on many possible PM alternatives • Cobalt compounds produced with wet chemical process

• MnBi, MnAl, MnFe, and others

• Exchange Spring mechanisms

• Fe16N2

• And others