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© ABBMonth DD, YYYY | Slide 1
ASHRAE Rocky Mountain Chapter VFD Fundamentals
April 16, 2010Jeff Miller -
2010
What is a Drive / VFD/ AFD?
0
230
460
Volts
Hertz30 60
460 V
60 Hz= 7.67
VHz
230 V
60 Hz= 3.83
VHz
If 230 VAC Power Line:
230 V Motor
460 V
Motor
What is a Drive?
Motor
L1
L2
L3
C
L
Input Converter(Diode Bridge)
Output Inverter(IGBT’s)
DC Bus(Filter)+
_+_
+
_
+
_
+ +
_ _
What is a Drive?
A variable frequency drive converts incoming 60 Hz utilitypower into DC, then converts to a simulated variable voltage, variable frequency output
VFD Fundamentals
60 Hz Power
Electrical Energy
ABB
Zero - 120 Hz
To Motor
VFD
RECTIFIER(AC - DC)
INVERTER(DC - AC)
AC DC AC
VFD
Zero - 120 Hz60 Hz
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
Area Under The Square-Wave PulsesApproximates The Area Under A Sine Wave
Frequency
Volta
ge
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
How Often You Switch From PositivePulses To Negative Pulses DeterminesThe Frequency Of The Waveform
Frequency
Volta
ge
Frequency = 30Hz
Frequency = 60Hz
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
Motor
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
Motor
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
Motor
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
Motor
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
Motor
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
Motor
RECTIFIER
PositiveDC Bus
NegativeDC Bus
+
-
INVERTER
Motor
Non-Linear Loads?• Loads which draw non-sinusoidal current from
the line:– Non-incandescent lighting– Computers– Uninterruptible power supplies– Telecommunications equipment– Copy machines– Battery chargers– Electronic variable speed drives – Any load with a solid state AC to DC power
converter
Typical AC Drive Configuration
M460VAC 3-phase
650VDC
Simulated AC
(PWM)
All AC Drives rectify AC to DC, then convert to simulated AC (PWM) to provide the motor Variable voltage and Frequency. The AC to DC conversion generates harmonics.
Harmonics — Definitions
• Non-linear loads draw current in a non-sinusoidal or distorted manner
• Harmonics or harmonic content is a mathematical concept implemented to allow quantification and simplified analysis of non-linear waveforms
• Harmonics are typically present in both network currents and network voltages
• Non-linear current draw creates non-linear voltage as it flows through the electrical network– Current harmonics Voltage harmonics
Harmonic Frequencies
Fundamental5th Harmonic7th harmonic11th Harmonic13th Harmonic17th Harmonic19th Harmonic
60 Hz300 Hz420 Hz 660 Hz780 Hz
1020 Hz1140 Hz
The Theory: Fundamental, 5th and 7th Harmonics
f1 60= w1 2p f1×= i1 t( ) 1 cos w1 t×( )×=
f5 300= w5 2p f5×= i5 t( ) 0.32 cos w5 t× p-( )×=
f7 420= w7 2p f7×= i7 t( ) 0.09 cos w7 t× p-( )×=
0 0.005 0.01 0.015 0.02 0.025 0.031
0.5
0
0.5
1
i1 t( )
i5 t( )
i7 t( )
t
Fundamental
5th
7th
iT t( ) i1 t( ) i5 t( )+ i7 t( )+=
0 0.005 0.01 0.015 0.02 0.025 0.031.5
1
0.5
0
0.5
1
1.5
iT t( )
t
Components
Summation
Harmonic Content, 6- Pulse DrivePWM Drive Harmonic Input Spectrum
5th
7th
Fundamental
11th13th
– Harmonic Current Distortion —• Added heating in transformers and
cables, reduces available capacity
• May stimulate a resonance condition with Power Factor Correction Capacitors
–Excessive voltage–Overheating of PF correction capacitors–Tripping of PF protection equipmentVoltage Distortion interfering w/ sensitive
equipment. Largest Concern!
Harmonics — Why worry?
– Harmonics produced by an individual load are only important to the extent that they represent a significant portion of the total connected load
– Linear loads help reduce system harmonic levels – TDD equals the THD of the nonlinear load multiplied by
the ratio of nonlinear load to the demand load:
Harmonics — A System Issue!
DLNLTHDTDD NL ×=Where
TDD = TDD of the systemTHDNL = THD of the nonlinear loadsNL = kVA of nonlinear loadDL = kVA of demand load
(nonlinear + linear)
Harmonics — By the Numbers
Table 10.2Low-Voltage System Classification and Distortion Limits
SpecialApplications
GeneralSystem
DedicatedSystem
Notch Depth 10% 20% 50%
THD (Voltage) 3% 5% 10%
Notch Area, mVs 16,400 22,800 36,500
Note: Notch area for other than 480 V systems should be multiplied by V / 480.
IEEE 519 - 1992
Harmonics — By the Numbers (cont.)
Table 10.3Current Distortion Limits for General Distribution Systems
ISC / IL <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
Note: All harmonic current levels are in percent with fundamental current IL as the base.
IEEE 519 - 1992
Harmonics — Attenuation Options• Reactors (Chokes)• Passive Filters
– Harmonic Trap– Hybrid
• High Pulse Count Rectification
• Active Filters– Drive Front End– Stand Alone
Reactors (Chokes)• Simplest and least
expensive harmonic reduction technique
• May be included in base drive package
• Often meet harmonic needs provided drive load is a small portion of total connected load
• May be implemented with AC line reactors or with DC link reactors– AC line reactors provide
better input protection– DC link reactors provide
load insensitive drive output voltage
– Both types provide similar harmonic benefits
• “Swinging” choke design provides enhanced light load harmonic performance
Reactors, AC Line or DC LinkAC LineReactor
M
DC LinkReactor
M
• Different design techniques
• Equal harmonic reduction for same normalized% reactance
• Typical full load THD (current) at drive input terminals28% 46%
Hybrid Filter• Installs in series with
drive input• May feed multiple
drives• Improves power factor
(may go leading)• Typical full load THD
(current) at filter input terminals5% 8%
• Relatively unaffected by line imbalance
High Pulse Count Rectification• Typical configurations are either 12 pulse or 18 pulse• Phase shifting transformer is required• Additional drive input bridge(s) is needed• Typical full load THD (current) at transformer
primary 8% 12% (12 pulse), 4% 6% (18 pulse)• Performance severely reduced by line imbalance
(voltage or phase)• Excellent choice if step-down transformer is already
required
High Pulse Count Rectification (cont.)
• 6 pulse rectifier
Transformer and cabling simple
Current very distortedIthd typically 45% with 3% reactor
DC/AC
DC/AC
Transformer and cabling complicated
Current distortedIthd 8% to 12% (depending on network impedance)
• 12 pulse rectifier
• 18 pulse rectifier
DC/AC
Transformer and cabling complicated
Current wave form goodIthd 4% to 6% (depending on network impedance)
Active Filter Front End with LCL Filter
LCL Filter (Sine Filter) removes high frequencies >1 kHz. (Current and voltage)
Full output voltage is available with 80% input voltage(400VIn = 480VOut)
Full regenerative capability No transformer required Not affected by line imbalance
LCL filter
Line inverter(rectifier)
Motor inverter Motor
L L
C
M
Remember!Even an 80% THD nonlinear load with a will result in only 8% TDD if the nonlinear load is 10% and the linear load is 90%.
(80%•(10%/(10%+90%))=8%)
Harmonic Reduction Summary
Effectiveness of Harmonic Mitigation Techniques (Assuming 100% Nonlinear Loading, ISC / IL = 60)
Technique THD (Current)
Harmonic Reduction
No mitigation (reference level) 72% 3% line reactors (or equivalent DC link reactor) 39% 45.8% 5% line reactors (or equivalent DC link reactor) 33% 54.2% 5% line reactors + 5th harmonic trap filter 12% 83.3% 12 pulse input rectifier with 5% impedance transformer 10% 86.1% Hybrid filter 7% 90.3% 18 pulse input rectifier with 5% impedance transformer 5% 93.1% 12 pulse input rectifier with 5% impedance transformer + 11th harmonic trap filter 4% 94.4%
Active harmonic filter 3.5% 95.1%
Summary – Practical Advice• With a main distribution transformer, 20-30% of its load
on non-linear loads will typically comply with IEEE 519-1992
• Voltage distortion causes interference with sensitive equipment, not current distortion!
• 5% reactors address 90+% of typical applications. They also provide protection against line transients and keep input currents low to avoid oversizing power wiring to comply with NEC.
• Make VFD vendor perform a harmonic distortion calculation with the submittals.
PEAK: 1,040 volts
Peak Voltage all at 50’ of cable
Peak Voltage has many Contributing Factors
Inverter Rated Motors Help Minimize the Issue
Less dV/dT minimizes; problems with RFI/EMI Motor Insulation & Bearing Current
Drive Peak Voltage
1 1040
2 1110
3 1180
4 1290
5 1350
6 2454
Recommendations
• Keep cable length short as possible• Use a NEMA MG1, Part 31 motor (not
“inverter duty” or “inverter ready”• Ensure that grounding is sound