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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 Rockwell Automation, Inc. (NYSE:ROK), the world’s largest company dedicated to industrial automation, makes its customers more productive and the world more sustainable. Throughout the world, our flagship Allen-Bradley® and Rockwell Software® product brands are recognized for innovation and excellence. Follow ROKAutomation on Facebook & Twitter. Connect with us on LinkedIn. 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.