Download 18-Pulse Low Harmonic Drive Packages

18-Pulse Low Harmonic
Drive Packages
Harmonic Mitigation Variable Frequency Drives
Harmonics – A Pressing Subject
Harmonics refer to deviations from the desired model sinusoidal AC line
voltage and the current waveforms. These deviations, or harmonic distortions,
historically were low in magnitude. However, more recently, there has been a
considerable increase attributed to the use of power electronics, non-linear
commercial and industrial loads, and Variable Frequency Drives (VFDs). These
deviations can influence the optimal performance of your connected devices.
Potentially Negative Effects
Solutions Simplified Through Innovation
The potential negative impacts of harmonic
distortions on electrical systems include, but are
not limited to:
• Component overheating
• Increase in supply transformer heat levels
• Random breaker tripping
• Shortened motor life
• Decreased device productivity
• Increased losses and reduced power factor can
lead to increased energy cost
In order to reduce distortions and prevent system
failures, facility engineers must mitigate harmonic
distortions at their source.
Fortunately, reduction of harmonic distortions to
acceptable levels is clear-cut.
• International Electrical and Electronics Engineers
(IEEE) guidelines are used to determine the
optimal level of harmonics in various systems
• Software tools are available that are used to
predict the level of harmonic activity and
evaluate mitigation solutions
Harmonic Mitigation Techniques
Meeting Your Specifications; Exceeding Your Expectations
Drive Harmonic
Mitigation Technique
2
Comments
18-Pulse Converter
with Auto
Transformer
Solution that meets IEEE 519-1992 standards at the drive input terminals without
analysis, when the balance of the power phases is within 0.5% (1% if required).
A patented autotransformer configuration will allow for a smaller size and lower
cost (easier to mount in the enclosure line-up) than an isolation transformer. Very
cost effective option above 100 horsepower.
Active Front End
Solution that actively monitors input current to maintain sine wave and meet
IEEE 519-1992 standards at input terminals of the drive. Is a cost effective option
on large common DC bus systems with multiple drives or high horsepower
rating requiring braking. Generally, most cost effective on medium voltage
applications.
Passive Power Filter
and 6-Pulse
AC drives
Is a cost effective solution on devices under 100 horsepower. Use caution when
applying this filter type with generator power sources. It may cause a power
system resonance condition in some installations.
Active Power Filter
External solution that actively monitors harmonic distortion levels and injects
cancellation harmonic currents onto the line in order to meet IEEE 519-1992 at
the input of the active filter connection. Cost effective solution on large common
AC bus functions.
Rockwell Automation Has Solutions
Avert potential system malfunctions by applying the proper
technology and solutions to minimize and limit the effects of harmonic
distortion on your devices. Rockwell Automation has developed a
wide array of methods to reduce harmonics caused by non-linear
loads. Several solutions are available that can be applied to meet your
harmonic requirements, facility limitations, and budget needs. Utilizing
low harmonic devices such as the 18-pulse, active front end, and active
and passive filters, in conjunction with the Allen-Bradley® PowerFlex®
drive systems, our solutions have proven effective and meet
IEEE 519-1992 standards.
Decreased Harmonics
Increase Your Productivity
Shown below is an actual representation of the voltage and current waveforms from
an application utilizing the Rockwell Automation 18-pulse VFD solution. Following
integration of the 18-pulse system, harmonic distortions are reduced to less
than 5%. The represented VFD is a 75HP, 60Hz, 480V PowerFlex 755.
PowerFlex 750 Series – 75HP @ 480V
Voltage
Current
Voltage 1->
(amps) 2->
Current
(amps)
1) CH1 200 V 5 ms
2) 50 A 5 ms
Time (msec)
3
Typical Layout
Forced Air
Ventilation
Input Circuit
Breaker
Operator
Devices
Interlocked
Disconnect
VFD
Rectifier
Air
Inlet
Filter
4
Bypass
Contactor
18 Pulse
Transformer
Advantages of a Rockwell Automation Solution
Low Voltage 18-Pulse PowerFlex 750 AC Drive Solution
Time-Tested Proven Technology
Highly Reliable and Consistent
PowerFlex family drives systems and
innovative technology components have
proven their effectiveness over the test of
time, representing over 30 years of design and
manufacturing experience.
The Rockwell Automation revolutionary
patented autotransformer will deliver the
highest quality outcome, while reducing
space used and decreasing costs through
reduced heat loss and are UL compliant.
Utilization of aluminum over copper for
transformer winding reduces production
costs and maintains the Rockwell Automation
high standards of performance.
The design of the patented autotransformer
topology sets Rockwell Automation ahead of
the competition.
• The 18-pulse solution reduces the potential
for unwanted interaction with your power
distribution system
• Conformal coating standard
• Drive design has less overall parts,
minimizing the chance of system failures
while maintaining high standards
of operation
• You can count on consistent high
quality performance throughout the
life of the product
• 18-pulse solution integrates passive
components to maximize product
reliability and simplicity
Robust Functionality
The Rockwell Automation 18-pulse solution
requires no set up and limited maintenance
time, to ensure maximum productivity of
your device.
With the most recent generation of IGBT
power technology, some power ratings and
sizes have been reduced, while still upholding
the Rockwell Automation high criteria for
efficiency and performance.
The inverter section has a user friendly
interface, utilizing a built in SMART™ menu,
allowing the user to program basic drive
settings, thus simplifying operations and
reducing training time .
The harmonic mitigation of the 18-pulse
solution can help reduce energy losses, thus
decreasing the amount of power needed and
increasing the device’s efficiency, which can
lead to cuts in your power costs.
All diagnostics integrated into an intuitive LCD
illuminated display with premier integration
communications and
software capabilities.
Enhance Your
Power Quality Monitoring
Versatile Application
To help improve productivity in any situation
or environment, the Rockwell Automation
Low Voltage 18-pulse drives are designed to
perform efficiently regardless if the source of
incoming power is on utility or generator.
Decrease Your Footprint,
Increase Your Productivity
The Allen-Bradley PowerMonitor™ family
provides cost-effective, compact, revenueaccurate microprocessor meters for
monitoring power quality and collecting
data on energy usage .
The meter provides real-time continuous
verification of compliance to IEEE-519
standards, communicated via RS-232, RS
485, DeviceNet, Remote I/O, EtherNet I/P,
or ControlNet. This feature allows for better
monitoring, controlling, and protection of
your important system equipment
and processes.
5
6
Enclosure Dimensions
DIMENSION CHART FOR POWERFLEX 750 NEME/UL1 ENCLOSURE DRIVE PACKAGE
Frame Pulse Protection
Normal Duty
Heavy Duty
Dimensions (Without Bypass)
Dimensions (With Bypass)
Approximate
(1)
Class/
Heat Loss
NEMA/UL HP Rating Max Amps Ambient Temp HP Rating Max Amps Ambient Temp Height x Width x Depth Appropriate Height x Width x Depth Approximate (Watts)
Out
Deg
C
Out
Deg
C
Weight
Weight
Rating
2
6
1 or 12
15
22
40
10
22
40
1219x762x409 MM
(48x30x16 inches)
101 KG
(221 lbs)
1219x762x409 MM
(48x30x16 inches)
114 KG
(251 lbs)
856
3
6
1 or 12
30
40
40
25
40
40
1219x762x409 MM
(48x30x16 inches)
117 KG
(257 lbs)
1219x762x409 MM
(48x30x16 inches)
127 KG
(279 lbs)
1269
4
6
1 or 12
50
65
40
40
65
40
1219x762x409 MM
(48x30x16 inches)
132 KG
(289 lbs)
1219x762x409 MM
(48x30x16 inches)
145 KG
(319 lbs)
2062
5
6
1 or 12
75
96
40
60
96
40
2324x762x635 MM
(92x30x25 inches)
502 KG 2324x1270x635 MM
(1105 lbs) (92x50x25 inches)
703 KG
(1546 lbs)
3118
6
18
1 or 12
200
248
40
150
248
40
2324x1397x635 MM 926 KG 2324x2032x635 MM
(92x55x25 inches) (2037 lbs) (92x80x25 inches)
2544 KG
(1157 lbs)
8054
7
18
1 or 12
350
415
40
300
415
40
2324x1651x635 MM 1490 KG 2324x2286x635 MM
(92x65x25 inches) (3278 lbs) (92x90x25 inches)
3594 KG
(1634 lbs)
13,788
8
18
1 or 12
650
617
40
500
740
40
2205x2600x605 MM 2008 KG 2205x3600x605 MM
(87x102x24 inches) (4417 lbs) (87x142x24 inches)
2257 KG
(4966 lbs)
24,587
General - The dimensions for frame 2 through 7 are based on MCC style enclosures. All frame sizes are also available in Rittal/Hoffman enclosures.
(1) - Most commonly used configurations shown for clarity. All frame sizes available in both 6 & 18 pulse configurations.
Harmonic Mitigation Solutions Checklist
18-Pulse Drive
Typical Current Harmonic Distortion (ITHD)
4.5-6%
6-Pulse Drive
Passive Filter
Active Filter
Active Front-End
20-45%
5-8%
3-5%
Yes
✔
Yes
✔
3-5%
Meet IEEE Special Applications
Yes
✔
No
✘
Marginal
Meet IEEE General Applications
Yes
✔
No
✘
Yes
✔
Yes
✔
Yes
✔
Meet IEEE Dedicated Applications
Yes
✔
Yes
✔
Yes
✔
Yes
✔
Yes
✔
Effect of 1% Voltage Unbalance
Marginal
Large
✘
Marginal
✔
Minimal
✔
Minimal
✔
No
No
Yes
*
No
No
Yes
*
No
0.75-0.95
0.3-1 Lead
*
0.90-0.99
Potential Low DC Bus
Potential System Resonance
No
No
No
0.90-0.99
✔
Efficiency
96.50%
✔
97%
✔
96.50%
✔
96%
96-97.5%
Cost Effective
>100 HP
✔
Good
✔
<100 HP
✔
Lg. System
<100 HP
2-6
3.5-5
2
Medium
Medium
Medium
Typical Total Power Factor; no/full load
Overall Size (Relative to 6-Pulse Drive)
3.3
Reliability
High
✔ Good
✘ May not meet IEEE 519-1992 standards
1
✔
High
✔
✔
0.8-1 Lead
✔
✔
* Application dependent
7
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Allen-Bradley, PowerFlex, PowerMonitor, Rockwell Software and SMART, are trademarks of Rockwell Automation.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Publication SSB-BR006A-EN-P – May 2012
Copyright © 2012 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.