Académique Documents
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Kelvin J. Hurdle
Art Kerchner
Input L p S1 S3 S5
Output
Sinewave D1 D3 D5 480 V,
480 V,
a b c V/Hz,
60 Hz
C Vbus 5 - 90 Hz
SMPS
D2 D4 D6
n S2 S4 S6
Fixed DC voltage
50.0 50.0
0 0
-50.0 -50.0
-100.0 -100.0
-150.0
• This
This isisan
anexample
exampleof aoflinear
a linear
load load -150.0
0 10.00m 20.00m 30.00m 40.00m
• Transformers Fundamental
(non-linear with over-voltage)
Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 6
What are Harmonics?
50.0 50.0
0 0
-50.0 -50.0
-100.0 -100.0
•• This
This isisan
considered
example of aa linear
non-linear
load load
-150.0 -150.0
0 10.00m 20.00m 30.00m 40.00m
Frequency [Hz] 60 Hz
Frequency [h] Fundamental 5th 7th 11th 13th 17th 19th
Current Harmonics
create
Voltage Distortion
Low-Voltage Systems
Application Maximum THD (%)
Special Applications - hospitals and airports 3.0%
General System 5.0%
Dedicated System - exclusively converter load 10.0%
Current distortion Limits for General Distribution Systems (120V through 69,000V)
Maximum Harmonic Current Distortion in Percent of Iload
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 5.0
20<50 7.0 3.5 2.5 1.0 0.5 8.0
50<100 10.0 4.5 4.0 1.5 0.7 12.0
100<1000 12.0 5.5 5.0 2.0 1.0 15.0
>1000 15.0 7.0 6.0 2.5 1.4 20.0
Even harmonics are limited to 25% of the odd harmonic limits above
Table 10.3
Isc=maximum short circuit current at PCC
Iload=maximum demand load current (fundamental frequency component) at PCC
Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 22
Harmonic Mitigation Techniques
Rockwell Automation
can assist in performing a software harmonic analysis,
recommend specific Harmonic Mitigation Solutions
and provide hardware quotations.
Standard Configuration -
current
“no” DC link Choke
T
1
T
) T • RFor Drives < 5e HP, no impact
f
on utility
2 ) R e f
Voltage
current
Standard Configuration -
“with” DC link Choke
• Current THD= 32% @ full load
• THD independent of source %Z
• Good power factor = 0.93
• Minimizes input voltage distortion
Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 25
Drive w/o DC Link Choke
Drive
• Typical I(THD) of 80 to Transformer
120% xfmr
%Z AC DC
• Sensitive to line voltage
DC AC
transients
• High peak line currents
Common
configuration for M
drives < 5hp hp
200.0 200.0
-200.0 -200.0
-400.0 -400.0
150.0m 162.5m 175.0m 187.5m 200.0m
Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 26
Drive with DC Link Choke
transients
M
hp
200.0 200.0
-200.0 -200.0
-400.0 -400.0
150.0m 162.5m 175.0m 187.5m 200.0m
Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 27
Line Reactor, Drive w/o DC Link Choke
Drive
• Typical I(THD) of 30 to 45% Transformer
• Big help for drives without xfmr
%Z AC DC
DC link choke
DC AC
Line Reactor
200.0 200.0
0 0 NOTE: shown is 3% LR
-200.0 -200.0
-400.0 -400.0
150.0m 162.5m 175.0m 187.5m 200.0m
Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 28
Line Reactor
200.0 200.0
0 0 NOTE: shown is 3% LR
-200.0 -200.0
-400.0 -400.0
150.0m 162.5m 175.0m 187.5m 200.0m
Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 29
Harmonic Mitigation Technique - Passive & Active
Filters
Passive Filters:
eliminate/reduce specific harmonics (tuned 5th, 7th filters)
reduce higher order harmonics (low pass, 5th thru 17th)
Active Filters:
using switching converters to compensate for specific
harmonics and/or improve Power Factor
It injects equal and opposite of Drive harmonics into AC
line
to 8% xfmr
%Z
Choke
AC DC
DC AC
M
hp
Passive Filter
100.0 100.0
50.0 50.0
0 0
-50.0 -50.0
-100.0 -100.0
-150.0 -150.0
-25.00m -20.00m -10.00m 0 10.00m 20.00m 24.90m
Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 31
Passive Harmonic Filter
DC AC
M
hp
Passive Filter
-25.00m -20.00m -10.00m 0 10.00m 20.00m 24.90m
Motor
150.0 Ia = f( S,... Load
100.0 100.0
50.0 50.0
0 0
-50.0 -50.0
-100.0 -100.0
-150.0 -150.0
-25.00m -20.00m -10.00m 0 10.00m 20.00m 24.90m
Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 33
Passive Filter: Harmonic Trap Filter
VSI
FEED
UTILITY AC DRIVE
XFMR.
Consists of one or more tuned 5th or 7th LC filters in shunt with power system.
Usually connected at the primary of the isolation transformer or line reactor.
Filters interact with other plant non-linear loads, can sink for unknown load.
Need overload and fuse blown detection (usually individually fused).
I filter
I filter
I source
DC AC
Iharm
AC
DC
M
Active Filter hp
Current from Transformer
Motor
-25.00m -20.00m -10.00m 0 10.00m 20.00m 24.90m Load
150.0 Ia = f( S,...
100.0 100.0
50.0 50.0
0 0
-50.0 -50.0
-100.0 -100.0
-150.0 -150.0
-25.00m -20.00m -10.00m 0 10.00m 20.00m 24.90m
Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 36
Active Harmonic Filter
AC Drive
Transformer DC Link
xfmr Choke
%Z Ifund Ifund + Iharm
AC DC
DC AC
M
Iharm
AC Drive
AC DC Link
Choke
DC
AC DC
Active Filter DC AC
M
DC Drive
AC
DC
M
12-Pulse Rectifier
18-Pulse Rectifier
• 18-pulse drives produce less THD, but are larger & more expensive
• Isolation transformers produce less THD, but larger & more expensive
AC DC
• 18-Pulse Typical DC AC
I(THD) of 4 to 5%
Multi-Phase
Transformer
M
hp
100.0 100.0
0 0
-100.0 -100.0
-200.0 -200.0
-25.00m -20.00m -10.00m 0 10.00m 20.00m 24.90m
Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 40
18-Pulse, Parallel
DC
M
AC
H1 X1 H6
+
X2 X9
H1 X1 400 400
X3 X8
H2 X2
H4 H3
X0
X4 X7
H3 X3
H2 X5 X6 H5
-
NOTE: 5 Autotransformer
windings per core leg
FEATURES
• Meets IEEE-519 5% Harmonic Standard at the
18 pulse input current drive input Terminal
• Current THD 3.5% full load (typ.), 6 % no load
• 5th, 7th, 11th & 13th harmonic reduced
• Input power factor improved to 0.99, thus
reducing kVA source requirements
18 pulse Utility input voltage • Input Diode rectifiers & magnetics lead to a
reliable drive system
• More robust and trouble free than
Harmonic Trap filters
• Specified for use on high “Z” Aux-Gen unit
• Lower $ than Active PWM Rectifier approach
• 18 pulse
– Diode bridge converter
– Common DC
bus drive
– Auto-transformer
to 5% xfmr
%Z AC DC
DC AC
M
hp
Notch Filter
145.0m
150.0m 162.5m 175.0m 187.5m
195.0m
Motor
200.0 Lx1.I = ... Load
100.0 100.0
0 0
-100.0 -100.0
-200.0 -200.0
145.0m
150.0m 162.5m 175.0m 187.5m
195.0m
Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 45
Active Front-End
• Serves as Input to Drive(s) 500.0
54.2m 60.0m 70.0m 80.0m 90.0m 100.0m 104.2m
I"LX1" = f(T...
VMRN = f(T...
– IEEE-519
• Regenerative 54.2m 60.0m 70.0m 80.0m 90.0m 100.0m 104.2m
– Energy Saving
500.0 I"LX1" [A] =...
VMRN [V] =...
0 0
-250.0 -250.0
-500.0
Regen -500.0
54.2m 60.0m 70.0m 80.0m 90.0m 100.0m 104.2m
Regenerative AC Drive
AC Motor Output
AC Line Input
Converter DC Inverter
AC to DC Bus DC to AC
Filter
Input
A dual-direction converter that ... Breaker
Input
choke
Output: 200A DC
Input: 460V AC, 145 kVA
(K-Code)
56
PowerFlex 7000 - Topology
There are three standard designs for the rectifier of the PowerFlex drive:
AFE
6 Pulse 18 Pulse or
Direct-to-Drive
(Confidential – For Internal Use Only) Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 57
Drives with AFE Technology
• Product Mix
– The Active Front End configuration continues to dominate sales by a wide margin
• No isolation transformer
• Best harmonic performance
• Best input power factor
3%
17%
6-Pulse
18-Pulse
AFE
80%
(Confidential – For Internal Use Only) Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 58
MV Drive Topology Comparison
Simple Complex
Very Complex
RECTIFIER L+ M+ INVERTER
SGCT’s SGCT’s
1) U (T1)
DC LINK
2) V (T2)
X3) W (T3)
L- M-
CSI-PWM 2 Level
•MV SGCT inverter
switch
•Low component count
•Simple power structure
•No phase shifting VSI-PWM Multi-Level
transformer •MV IGBT inverter switch
•High component count VSI-PWM Multi-Level (Series Cell)
•Complex Power structure and •LV IGBT inverter switch
transformer configuration •Very high component count.
•Complex output filter •Very Complex power structure and
transformer configuration
rectifier Inverter
load
• Output:
– PWM-CSI with SHE patterns, eliminating 5th, 7th and 11th to rated frequency with
switching frequency of 420hz
• Input:
– AFE bridge eliminates 5th, 7th, 11th harmonics (SHE pattern)
– results in low input current THD using 420Hz switching frequency
– input capacitance filtering harmonics above 11th and providing capacitance for
reactive power compensation (improved PF)
– reactor on line side of capacitor isolating the drive from the line
• current limiting features
• further filtering
0.5
• SHE eliminating 5th, 7th and 11th harmonics with phase shifting switching
frequency is 420Hz
• each symmetric switching pattern eliminates one harmonic
Line current
Line-to-line voltage
Input Current
AFE
18%
16% Input Voltage
14%
12%
6-Pulse
10%
8% 12-Pulse
6%
4% 18-Pulse
2% AFE
0%
5th 7th 11th 13th 17th 19th 23rd 25th
Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 66
PowerFlex 7000 – Features and Benefits
Drive Performance - Motor Friendly
• Near sinusoidal current and voltage @ all speeds and
loads
– no additional motor heating or voltage stress to insulation
compared to sine wave operation
• Compatible with standard motors
– induction or synchronous motors
– no de-rating
– inverter duty motor not required
– new or retrofit applications Typical VFD output waveforms @ full load, full speed
• Virtually unlimited motor cable distance •4160V, 933 kW, 60 Hz
– stable operation up to 15 Km •Top - Motor Current
Rockwell Automation has changed all of that with its DIRECT-TO-DRIVE Technology!