Download Embedded Solutions Through Targeted Power Conditioning

Embedded Solutions Through
Targeted Power Conditioning
Mark Stephens, PE
Manager
Industrial Studies
Electric Power Research Institute
942 Corridor Park Blvd
Knoxville, Tennessee 37932
Phone 865.218.8022
[email protected]
Cost of Solutions Versus Knowledge of
Sensitivity
© 2009 Electric Power Research Institute, Inc. All rights reserved.
2
Example PQ Solution Levels
Machine or Subsystem Level
Power Conditioning
© 2009 Electric Power Research Institute, Inc. All rights reserved.
Control Level
Power Conditioning
Control Level
Embedded DC Solution
(1/10th to 1/20th of Machine Level Power Conditioner Cost)
(Best done by OEM in design phase)
3
Embedded Solution Strategies
Batteryless Ride-Through Devices
(BRTDs)
•
Use “Selective Power
Conditioners” on
susceptible loads
CVT and
PowerRide RTD DPI and VDC
DySC
Low Voltage
CoilLock Ride Through
Module
•
Embed the Solution through proper
design, configuration and component
selection strategies
Vacuum
Pumps
•
Utilize a Combination of both
strategies
© 2009 Electric Power Research Institute, Inc. All rights reserved.
4
DC
Power
Contactors Supplies
Relays
“Selective” Conditioning
The Premise:
All equipment power users are not ultra-sensitive.
The Plan:
To prop up the single-phase “weak links” only.
The Weak Links:
Small, single-phase 100Vac-230Vac, typically power
supplies, sensors and controls.
The Benefit: Lower Cost than Macro Solutions.
© 2009 Electric Power Research Institute, Inc. All rights reserved.
5
Uninterruptible Power Supply (UPS)
For Control Loads
Small 500Va to
3kVA
UPS Systems are
sometimes Used
Battery Based
UPS
Are Often
“Overkill”
© 2009 Electric Power Research Institute, Inc. All rights reserved.
6
“Abandoned in Place” UPS Systems
• Throughout our numerous onsite power quality audits we
have found many UPS systems
“abandoned in place” when
their batteries expire
• Without proper maintenance,
UPS solutions are not effective
© 2009 Electric Power Research Institute, Inc. All rights reserved.
7
UPS Application & Features
• Off-line (standby) & On-Line models.
• Must consider in-rush current for On-line models.
• Some units have Square Wave Output During Voltage Sag
• Sub-Cycle to several cycle Response. Some critical control
components can drop out within 1/4 cycle.
• Sizing for battery time and in-rush current of UPS is
manufacturer specific.
• Protects against voltage sags and outages.
© 2009 Electric Power Research Institute, Inc. All rights reserved.
8
Square Wave Compatibility
with PLCs
PLC Model
Compatible
with 120Vac
Input Cards?
Outcome with
APC Smart UPS 420
Outcome with
APC Back UPS Pro 650
Omron (PLC A)
No
Toggling input could not
be resolved
Toggling input could not
be resolved
TI 545 (PLC B)
No
All inputs dropped
leading to the logical
decision to drop the
control relay
All inputs dropped
leading to the logical
decision to drop the
control relay
Quantum (PLC C)
No
Same as TI 545
Same as TI 545
AB PLC-5 (PLC D)
Yes
No Effect, System OK
AB SLC 5/03 (PLC E)
© 2009 Electric Power Research Institute, Inc. All rights reserved.
Yes
No Effect, System OK
9
No Effect, System OK
No Effect, System OK
UPS Coverage vs.
Sample Historical Data
© 2009 Electric Power Research Institute, Inc. All rights reserved.
10
Constant Voltage Transformer (CVT)
© 2009 Electric Power Research Institute, Inc. All rights reserved.
11
CVT Application & Features
•On-line Device. In-Rush Current
of load(s) MUST be considered in sizing.
Output of CVT can collapse when in-rush current
gets close too high ( around 4 x rated size).
• Sub-Cycle Response.
• Should be oversized to at least 2 times nominal
of load to increase ride-through.
• Acts as an isolation transformer and
protects against voltage sags.
© 2009 Electric Power Research Institute, Inc. All rights reserved.
12
Example CVT Installation
© 2009 Electric Power Research Institute, Inc. All rights reserved.
13
Output Voltage
Input Voltage
CVT Output
© 2009 Electric Power Research Institute, Inc. All rights reserved.
14
Sample CVT Sizing
Recommendations
Specs
Recommended Max
Nominal Load VA/
Current @ 120Vac
Recommended Max
Inrush Load VA
Current @ 120Vac
Dimensions (inch)
Weight (lbs)
250VA
100 VA / 0.83 A
500VA
200 VA / 1.67 A
1kVA
400 VA / 3.33 A
3kVA
1200 VA / 10 A
500 VA / 4.16A
1000 VA / 8.33A
2000 VA / 16.67 A
6000 VA / 50A
9.88x4.5x7.44
27
12.69x7.78x6.44
37
16.75x7.78x6.44
62
18.69x10.56x9.03
142
MIN SIZE = 2.5 X Nominal VA
or
1/2 Max Inrush VA*
(whichever is larger)
*most critical with contactor loads
© 2009 Electric Power Research Institute, Inc. All rights reserved.
15
Example CVT Application
• The CVT is protecting only
the AC control components
means that the selected
power conditioner will be
more affordable than one that
could protect the entire
machine.
• The ride-though of the AC
drives in this example can be
enhanced by modifying their
programming, thus eliminating
the need for a large power
conditioner.
© 2009 Electric Power Research Institute, Inc. All rights reserved.
16
CVT Coverage vs.
Sample Historical Data
© 2009 Electric Power Research Institute, Inc. All rights reserved.
17
CVT Typical Costs ($USD)
Constant Voltage Transformer (CVT)
(Sola/Hevi-Duty. Ph: 1-800-377-4384, www.sola-hevi-duty.com )
120 VA Catalog No: 63-23-112-4, Cost $245, (8.62” X 3.31 “ X 5.18 “, 15 lbs)
250 VA Catalog No: 63-23-125-4, Cost $400, (9.88” X 4.50” X 7.44”, 27 lbs)
500 VA Catalog No: 63-23-150-8, Cost $650, (12.69” X7.78” X 6.44”, 37 lbs)
750 VA Catalog No: 63-23-175-8. Cost $700, (13.69” X 7.78” X 6.44”, 52 lbs)
1000 VA Catalog No: 63-23-210-8, Cost $850, (16.75” X 7.78” X 6.44”, 62 lbs)
1500 VA Catalog No: 63-23-215-8, Cost $1100 ( 16.44” X 10.56” X 9.03”, 95 lbs)
2000 VA Catalog No: 63-23-220-8, Cost $1200 (17” X 11” X 9”, 109 lbs)
5000 VA Catalog No: 63-23-250-8, Cost $2907 (28” X 11” X 9”, 222 lbs)
7500 VA Catalog No: 63-28-275-8, Cost $3829 (28” X 24” X 9”, 362 lbs)
15,000 VA Catalog No: 63-28-315-8, Cost $6700 (28” X 36” X 9”, 710 lbs)
© 2009 Electric Power Research Institute, Inc. All rights reserved.
18
New Product: UPPI PowerRide RTD
Basically a CVT on Steroids!
•
Uses two phases of a
three-phase supply as
input and a single-phase
output.
•
If one phase in
interrupted, constant
power out of the
RTD....Even if the
remaining phase drops
by a third.
•
Typically No Need to
oversize for Inrush
© 2009 Electric Power Research Institute, Inc. All rights reserved.
19
UPPI PowerRide RTD:
How It Works
Power Anomaly
Result
Output remains constant
Output remains constant
Output remains constant
Output remains constant
Loss of Phase A
Loss of Phase B
Loss of Phase C
Loss of Phase A and B 33% sag on remaining phase
Loss of Phase B and C 33% sag on remaining phase
Loss of Phase A and C
Loss of A and 33% Sag on C
Loss of C and 33% Sag on A
37% Sag on A and C
© 2009 Electric Power Research Institute, Inc. All rights reserved.
Output remains constant
Output goes to 0
Output remains constant
Output remains constant
Output remains constant
20
UPPI PowerRide RTD:
Example Output
© 2009 Electric Power Research Institute, Inc. All rights reserved.
21
UPPI PowerRide RTD: Suggested List Price
Product
Size
Qty
Suggested
List Price
500va
1
2-9
10 +
$779
$677
$589
1kva
1
2-9
10 +
$1,180
$1,026
$892
2kva
1
2-9
10 +
$2,011
$1,748
$1,520
3kva
1
2-9
10 +
$2,881
$2,505
$2,178
5kva
1
2-9
10 +
$4,503
$3,916
$3,405
7kva
1
2-9
10 +
$4,845
$4,404
$4,004
10kva
1
2-9
10 +
$7,893
$7,175
$6,523
© 2009 Electric Power Research Institute, Inc. All rights reserved.
http://www.uppi-ups.com
22
Power Ride RTD Coverage vs.
Sample Historical Data
(Red Box is coverage for Single-Phase Sags & Phase
to-Phase Sags (A-B, B-C) Blue Box for Phase-to-Phase Sags (A-C)
© 2009 Electric Power Research Institute, Inc. All rights reserved.
23
The Dip Proofing Inverter
• No batteries; therefore, no replacement
and maintenance costs or hazardous
waste.
• Fast (<700µS) transfer, off-line system
develops little heat & fails to safety.
• Able to withstand high inrush currents; no
need to oversize as with UPS’s & CVT’s.
• Lightweight, small & easy to retrofit; no
step-up transformers or batteries.
• Accurate application control; adjustable
ride through time & variable transfer level.
• Primarily designed for inductive and low
power factor loads.
© 2009 Electric Power Research Institute, Inc. All rights reserved.
24
Typical Connections
© 2009 Electric Power Research Institute, Inc. All rights reserved.
25
Sample DPI Specifications
(120V Models)
Specs
Nominal Load
Current
Useable Stored
Energy
Ride-Through
Timer Range
Transfer Level
Range
Dimensions (inch)
Weight (lbs)
© 2009 Electric Power Research Institute, Inc. All rights reserved.
250VA
2A
500VA
4A
1kVA
8A
3hkVA
25A
45J
90J
180J
540J
0.01 to 2.56 Seconds
7.68x12.25x6.4
11
50% to 80%
50% to 90% Recommended (Special Order)
11.4x12.25x6.4
15.75x12.25x6.4
21x12.25x6.4
17
22
31
26
DPI Output
Output Voltage
Input Voltage
Square Wave not compatible with some PLC AC Input Cards.
•1-3 second ride-through based on real power required and sizing.
© 2009 Electric Power Research Institute, Inc. All rights reserved.
27
DPI Used in Chiller Control Circuit
DPI
© 2009 Electric Power Research Institute, Inc. All rights reserved.
28
DPI Coverage vs.
Sample Historical Data
© 2009 Electric Power Research Institute, Inc. All rights reserved.
29
DPI Typical Costs
© 2009 Electric Power Research Institute, Inc. All rights reserved.
30
Voltage Dip Compensator (Vdc)
•
No batteries; no maintenance.
•
Fast compensation.
•
Able to withstand high inrush
currents.
•
Small footprint, easy to retrofit.
•
Support exceeds SEMI F47
standard requirements.
•
Handles inductive and low power
factor loads.
•
120Vac and 208Vac Models
•
Currently under evaluation by EPRI
PEAC
© 2009 Electric Power Research Institute, Inc. All rights reserved.
31
VDC Output
AC Output is a Sine Wave
instead of a Square Wave
Product by Dip Proofing
Technologies
www.dipproof.com
www.measurlogic.com
© 2009 Electric Power Research Institute, Inc. All rights reserved.
32
4T Model – Down to 50%
VDC Coverage
6T Model – Down to 37%
© 2009 Electric Power Research Institute, Inc. All rights reserved.
33
VDC Coverage (4T Model) vs.
Sample Historical Data
© 2009 Electric Power Research Institute, Inc. All rights reserved.
34
Typical VDC Pricing
© 2009 Electric Power Research Institute, Inc. All rights reserved.
35
Dynamic Sag Corrector
MegaDySC
Three-Phase Protection
• Draws power from remaining
sagged voltage down to 50% of
nominal voltage, and injects a
series voltage to regulate a
sinusoidal output voltage
400-3200Amps
• Below 50%, draws power from
internal storage capacitors
• Mega and Pro DySC have on
board event logging.
ProDySC
Three-Phase Protection
25-200Amps
MiniDySC
Single-Phase Protection
1-50 Amps
© 2009 Electric Power Research Institute, Inc. All rights reserved.
36
Example DySC Output
500
400
300
200
100
0
Input Voltage (Van)
- 100
- 200
- 300
- 400
- 500
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0.45
0.5
t ( s)
500
300
Missing Volts
100
- 100
- 300
- 500
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0.45
0.5
t ( s)
600
400
DySC Output Voltage
200
0
- 200
- 400
- 600
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
t ( s)
© 2009 Electric Power Research Institute, Inc. All rights reserved.
37
0.4
0.45
0.5
Voltage Sag Correction & Ride-Through Times
• Ride-Through Times: (Based on
100% load, 0.7PF at 60Hz line
frequency)
• Standard Runtime:
2 seconds for sags from 87% to
50% of nominal voltage every 60
seconds
– Up to 5 seconds coverage on
Extended Run-Time Models
• 3 cycles for Standard Outage units
from 50%-100% (zero voltage
remaining)
• 12 cycles for Extended Outage
units from 50%-100% (zero
voltage remaining)
© 2009 Electric Power Research Institute, Inc. All rights reserved.
38
Extended Run-Time Models Are Available
© 2009 Electric Power Research Institute, Inc. All rights reserved.
39
Extended Run-Time Models Are Available
© 2009 Electric Power Research Institute, Inc. All rights reserved.
40
MiniDySC Coverage vs.Sample Historical Data
Orange – Extended Ride-Through Full Load
Red – Standard Ride-Through Full Load
© 2009 Electric Power Research Institute, Inc. All rights reserved.
41
MiniDySC Typical Cost
www.softswitch.com
1.5kVA 120Vac Single Phase MiniDySC DS10012A120V2SH1000A $2000.00
3kVA 120Vac Single Phase MiniDySC
DS10025A120V2SH1000A $2820.00
6-7kVa 120Vac Single Phase MiniDySC DS10050A120V2SH1000A $4570.00
© 2009 Electric Power Research Institute, Inc. All rights reserved.
42
New Product - WaveSync – Ride Through
Controller
• The WaveSync was
developed by Bay Controls
(the parent company of
Phase Solutions) R&D based
on research conducted by
Advanced Energy. It was
developed as a solutions to
the problem of motor ride
through during momentary
power interruptions.
• www.phasesolutions.com
© 2009 Electric Power Research Institute, Inc. All rights reserved.
43
WaveSync Operation
•
The WaveSync performs four primary operations to
accomplish ride through.
1. Monitor supply power to detect the beginning of a
momentary outage event.
2. Open the motor contactor upon event detection.
3. Keep any motor control center associated with the
protected motor “alive” during the event.
4. Once the event has ended, re-close the motor contactor at
the appropriate time, preventing torque and current spikes.
5. Can be setup to treat voltage sag like and outage and
perform same function
© 2009 Electric Power Research Institute, Inc. All rights reserved.
44
During the Momentary Interruption
• The WaveSync is working during a momentary interruption.
– Monitoring the three phase supply power and,
– Monitoring the three phase motor back EMF,
– Supplying power and a run signal to any motor control
center
– Reconnection of power when supply and motor back EMF
are in phase, or upon decay of back EMF at or below a
predetermined level.
– REQUIRES POWER CONDITIONER TO KEEP
WAVESYNC POWERED DURING MOMENTARY
INTERRUPTION (such as DPI).
© 2009 Electric Power Research Institute, Inc. All rights reserved.
45
During Voltage Sags
• The WaveSync is configured to handle voltage sags below a
preset value as a momentary outage.
• The device will hold in the contactor during sags at or above
the outage setting.
• During long duration sags, motors are protected utilizing
existing over current protection - the WaveSync does not
interfere with motor protection systems
© 2009 Electric Power Research Institute, Inc. All rights reserved.
46
Reconnecting Power in Phase
Cycles
55
60
65
70
75
1000
800
600
400
Volts
200
0
200
400
600
800
1000
Supply Voltage Restored
Motor Contactor Energized
Motor Energized Safely (In-Phase)
© 2009 Electric Power Research Institute, Inc. All rights reserved.
47
80
Coil Hold-in Devices
• Designed to “Prop Up” individual relays and
contactors. Available at 24, 120, 230 and 480Vac.
• Holds in down to 10 to 20% of %Vnominal.
• Ideal for Motor Control Center Applications.
• Size Based on Voltage and Coil Resistance.
• Cost: less than $100 per unit
© 2009 Electric Power Research Institute, Inc. All rights reserved.
48
CoilLock
Low Voltage
Ride Through
Module
Coil Hold-In Device Ride-Through Curve
© 2009 Electric Power Research Institute, Inc. All rights reserved.
49
Coil Hold in Device Application
© 2009 Electric Power Research Institute, Inc. All rights reserved.
50
Sizing Coil Hold In Devices
www.scrcontrols.com
www.squared-semi.com
www.pqsi.com
SIZED BASED ON
Actual Semi Tool Relays with KnowTrips Recommended.
Name
Contactor
K1
Contactor
K2
K15
K16
K17
K18
K20
K22
K23
Manufacturer
Information
Gould Cat
2250H15
Gould Cat
2250H15
Gould 2210DP
Cutler Hammer
D5PR3A
(ice cube)
Gould 2210DP
Cutler Hammer
D5PR3A
(ice cube)
Cutler Hammer
D5PR3A
(ice cube)
Gould 2210DP
Gould 2210DP
© 2009 Electric Power Research Institute, Inc. All rights reserved.
Phase
Ref
KnowTrip
Model
φΑ
Coil
Resistance
(ohms)
10.5
φΑ
10.5
120
φΑ
φΒ
326
>800
120A
120B
φΒ
φC
326
>800
120A
120B
φΒ
>800
120B
φΑ
φΑ
326
326
120A
120A
51
120
1. AC Coil Voltage
2. Resistance of Coil
Model 120: 8-200 ohms
Model 120A: 201-800 ohms
Model 120B: 801+ ohms
Overview of Power Quality Coverage
Type of
Event
DPI
VDC
CVT
RTD
MiniDySC
UPS
Coil Hold-in
Devices
Spikes and
Surges
No
No
Solves
Solves
Solves
Solves
Yes (Coil Lock)
No (Knowtrip)
Sags to
80% of
Nominal
Voltage
Solves
Solves
Solves
Solves for a
single phase
events and
most two
phase
events
Solves
Solves
Solves
Sag to
50-80% of
Nominal
Voltage
Solves
Solves
Solves
Depending
on Sizing
of Device
Solves for a
single phase
events and
most two
phase
events
Solves
Solves
Solves
Sags to 2550% of
Nominal
Voltage
Solves
No
Solves
Depending
on Sizing
of Device
Solves for a
single phase
events and
most two
phase
events
Solves
Solves
Solves
Outage
Solves time
depends
on load
and unit
size
No
No
Solves for a
single phase
events
Solves time
depends
on load
and unit
size
Solves
No
© 2009 Electric Power Research Institute, Inc. All rights reserved.
52
Power Conditioner Web Sites
Batteryless Ride-Through Devices (BRTD)
Standby Inverter
Dip-Proofing Technologies
Technology
www.dipproof.com
www.measurlogic.com
Active Ferro
Technology
Uninterruptible Power Products www.uppi-ups.com
(UPPI)
DC bus hold-in
Technology
Bonitron
www.bonitron.com
DC bus hold-in
Technology
Maxwell Technologies
www.maxwell.com
Coil and Relay hold-in Power Quality Solutions
products
www.pqsi.com
Coil and Relay hold-in SCR Controls
products
www.scrcontrols.com
Voltage Compensation Soft Switching Technology
Technology
www.softswitch.com
© 2009 Electric Power Research Institute, Inc. All rights reserved.
53
Power Conditioner Web Sites (continued)
Constant Voltage Transformers (CVT)
BEST Power
www.bestpower.com
Sola
www.sola-hevi-duty.com
Shape Electronics
www.shapelectronics.com
Controlled Power
www.controlledpwr.com/
Power Quality Solutions
www.pqsi.com
UPPI (PowerRide-RTD)
www.uppi-ups.com
Uninterruptible Power Supplies (UPS)
Standby, LineAPC
interactive
www.apcc.com
Standby,Lineinteractive,
Ferroresonant
BEST Power
www.bestpower.com
Standby, On-line
Exide
www.exide.com
Standby, On-line
Liebert
www.liebert.com
On-line
Clary
www.clary.com
Standby
Tripplite
www.tripplite.com
On-line
MGE UPS Systems
www.mgeups.com
Rotary
Piller
www.piller.com/
© 2009 Electric Power Research Institute, Inc. All rights reserved.
54