Documente Academic
Documente Profesional
Documente Cultură
Tommy Eitenmiller
Business Developer
MV Drives
Siemens Industry, Inc.
Siemens Industry, Inc. 2016 All rights reserved. 1
MIA Detroit 2016
Why VFDs
According to the U.S. Department of Energy, motors account for 70% of all energy
consumed by the domestic manufacturing sector and use over 55% of the total
electric energy generated in America.
Large electric motors, those greater than 1000 horsepower, consume over 25% of
the total generated electric energy.
A motor will use 10 to 20 times its capital cost in energy cost per year
Motors used on pump and fan applications are the biggest power users.
Large energy savings are realized by changing these loads from constant speed
to variable speed Retrofit market is as high as 70% in some regions with 1 -2
years payback
180
160
This HP Difference is the
140 Energy Required to Push
120 the Fluid Past the Valve
100
80
60
40
20
0
1 2 3 4 5 6 7 8 9 10 11
Elimination of belts and gears or other power transmission devices by matching the base
speed of the motor to the driven load.
Automation of process control by using the VFD as the final control element, leading to
more efficient part-load operation.
Reduction of the rating and cost of the electrical distribution system by eliminating motor
starting inrush.
Reducing noise and environmental impact--electric drives are clean, non-polluting, quiet,
efficient, and easy to repair.
Siemens Industry, Inc. 2016 All rights reserved. 7
MIA Detroit 2016
Limited harmonic content, particularly at the lower harmonics. This lowers I2R
losses and reduces torque pulsations.
Fortunately, motors are inductive, so that they function as good low-pass filters.
This permits the technique of moving harmonics to higher frequencies.
Reasonably low dv/dt on the motor terminals, so the voltage step does not
appear across the first few turns of the coil nearest the terminal.
Pros Cons
The motor is isolated from the line Low order harmonics can add to
and is not affected by line motor losses and create torque
unbalance or transients. pulsations.
Definition of Topology
Typical LV VFD
DC Link
VAC
Vmotor
VDC
IAC
IAC
Imotor
IDC
A meaningful differentiation can be made according to the configuration of the DC link. The
DC link largely isolates the operation of the converter from the inverter. The input converter
determines the power factor and harmonics, while the inverter determines the machine-
side properties.
AC
Converter without DC-link AC
Cycloconverter
Matrix Converter
Choke / Inductor
AC
Voltage Source Inverters (VSI) =
DC
=
DC
AC
Voltage-fed VFD
The DC link electrolytic capacitors can
be a reliability and lifetime issue.
There are only a few types of power Power conversion equipment consists of
conversion circuits which are widely one or more of these basic circuits.
used:
Medium-voltage drives almost always
Voltage transformation is frequently
consist of two of these processes,
incorporated into power conversion
rectification and inversion in sequence.
equipment as dedicated
transformers e.g., Perfect Harmony.
Rectification is the conversion of
fixed frequency, fixed voltage AC
power into fixed or variable voltage
DC power.
Inversion is the reverse of
rectification: changing DC power
into AC power.
These active switching devices are combined with passive components like
resistors, inductors (chokes) and capacitors.
Siemens Industry, Inc. 2016 All rights reserved. 17
MIA Detroit 2016
Line-Side Converters
Line-side converters change fixed voltage, fixed frequency AC power from the
utility to DC voltage. They can be constructed of:
The utility properties are mostly affected by the line-side converter only
because the DC link separates the effects of the machine-side converter.
The current-fed power factor is affected by the load power factor and speed.
VA IA I1 I3 I5
VB IB
N RL VDC IDC
VC IC
VDC
Sources of Harmonics
Effects of Harmonics
Rectifier Inverter
12-pulse Transformer Phase Shifts:
12-Pulse: 30 deg.
Capacitor
DC Link
Phase Shifting
Three Winding
Transformer M 18-Pulse: 20 deg.
0 deg.
3-Phase 24-pulse: 15 deg.
Induction Motor
3-Phase
Supply 30-pulse: 12 deg.
+30 deg.
Rectifier Inverter
18-pulse
Capacitor
DC Link
M
Phase Shifting
Four Winding 3-Phase
Transformer Induction Motor
Characteristic Harmonics: h = kq 1
+20 deg.
h = characteristic harmonic
3-Phase
k = any integer Supply 0 deg.
Typical Current THD:
q = pulse number 6-Pulse: 25% - 50%
-20 deg.
6-Pulse: h = k x 6 1 = 5,7,11,13,17,19,23,25 12-Pulse: 8% - 12%
+30 deg.
12-Pulse: h = k x 12 1 = 11,13,23,25,35,37 18-Pulse: 3% - 5%
18-pulse: h = k x 18 1 = 17,19,35,37
THD = 43.6%
THD = 8.8%
THD = 3.9%
18-Pulse VFD Input Current
Although the current can flow in one direction only, when >90 the link voltage changes
polarity and energy flows back to the line (regeneration).
The phaseback angle becomes the phase delay of the AC input current; so the
displacement power factor of the Thyristor converter is cos . (not always good)
Because commutation can occur when the line to line voltage is high, the input current
changes rapidly giving rise to high order harmonics, as compared to the rectifier bridge.
Because there is voltage ripple on the output, they must be loaded by some amount of
DC link inductance.
Thyristor converters are simple, cheap, and reliable and can be built in extremely
large ratings.
To Inverter
3-PHASE MV
INPUT
Voltage
Current
0.8
0.6
0.4
0.2
0
0 5 10 15 20 25 30 35 40 45 50 55 60
Output
Frequency
Inverter Principles
The function of the inverter is to change the DC link voltage (or current) into
AC voltage (or current) of sufficient quality to operate the motor. Both
frequency and amplitude must be controlled.
In the voltage-fed circuits, both amplitude and frequency are controlled by the
output switches when a rectifier input is used.
PWM Principles
Since our switches must be either fully on or off, we can only produce
discrete pulses and/or levels at the output.
Starting with the basic square wave which has 50% odd harmonics, we can
eliminate harmonics by putting additional notches in strategic positions.
Each additional pair of switchings enables the elimination of another
harmonic.
PWM Strategies
There are a huge number of PWM strategies each with its own set of
advantages and disadvantages. There are 3 categories:
Motor
frequency
Motor
determined
Voltage
by output
determined
inverter
by converter
All drives save money for fan and pump loads, but not all drives
save money equally.
Taking the numbers from the example above and using an average of $0.10 per
kWh, the difference can add up quickly: more than $150,000 over five years.
Banks tuned to an operating point based on CSI and utility impedance at site
performance degrades away from that ideal operating point
If utility impedance changed, filters likely need retuning, reworking, Increased cost of
ownership
Poor power factor and harmonics generated by the CSI input require very large K-
rated transformers or reactor/filter banks
Potential motor issues due to common mode voltage when using a transformer-less
design.
Siemens Industry, Inc. 2016 All rights reserved. 44
MIA Detroit 2016
4000V step
1 2 3 4 5
2000V step
For the dimensioning of the sine filter the following points have to be considered:
The reactor on the inverter side is defined in such a way, that the inverter ripple current remains
acceptable
The utility side reactor should be selected to sufficiently limit any short-circuit currents
The filter capacitor is selected in such a way, that the resonance frequency stays close to nine
times the fundamental in every operation point.
motor voltage
motor current
No output filter
A1
B1
C1
A2
B2
C2
A3
B3
Input from Power
C3 transformer output
Secondary of cell
A4
B4
C4
A5
B5
uL1
A1
B1 A5
C1
A2
A4
B2
A3
C2
A3 uL1-N uL1L3
A2
B3
or
C3 A1
A4 1200 1200
B4
B1 1200 C1
C4
B2 C2
A5 B3 C3
B5 B4 C4
C5 B5 C5
uL2 uL3
M
2 cells pulled
3 cells inserted
Siemens Industry, Inc. 2016 All rights reserved. 51
MIA Detroit 2016
DIT Primary
Winding DIT
Secondary
Windings
Induction or
Synchronous
MOTOR
VFD Cell
Groups
No dV/dt problems
Drive creates no motor voltage insulation stress
60
50
40
Temp Rise (degF)
30
MG Set
VFD
20
10
-10
400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600
Speed (RPM)
When the control detects that a cell has failed, a command can be sent to close
the appropriate contactor.
This simultaneously disconnects the cell output from the circuit and connects
the two adjacent cells together, effectively taking the failed cell out of the circuit.
The drive can then be restarted and operation can continue at reduced capacity
failure
example 1
The table below shows the output voltage capability of a GH180 drives. The gray
columns capture the output voltage capability if cells are bypassed at random,
assuming full line voltage is available. The highlighted column shows the voltage
capability if one cell is bypassed per phase, assuming full line voltage available.
Contact Information
Tommy Eitenmiller
Business Developer, MV Drives
Technical Business Development
Mobile: 678-427-3347
E-mail: thomas.eitenmiller@siemens.com