ATV71-61 Active Front End V2 S09

Active Front End

STI - Power DrivesSeptember 2009

Schneider Electric 2 - Engineered Drives - Martin Gradner – March 2009

Active Front End (AFE)

Feedback energy

Reduce energy costs

Increase power quality

Harmonic mitigation

… is an option to Altivar ATV61 and ATV71 range


Application examplesGantry crane

Water pump

Downhill conveyors

Escalators

Fans

Supply pumps


Two main fields of application

● Hoisting ● Downhill conveyors ● High inertia and high dynamic applications● Test stands● Winches

Regenerative operation

● Weak mains supply● Utilization of full transformer power● Generator supply● Compliance to IEEE 519● Unstable mains conditions

Harmonic mitigation


AFE – some technical basics I

t

t

motor cos =1

t

t

generator cos = -1

L1 UL2 VL3 W

Intelligent Rectifier+ Line Filter

InverterIGBT bridge


AFE – some technical basics II

● AFE works like a step up chopper

● AFE changeover from motor to generator operation shock-free

● AFE has a sinusoidal mains current

● AFE always needs line filter components


Components of the AFE

LFM – Line Filter Module

LFC – Line Filter Choke

AIC – Active Infeed ConverterAFE

AIC Active Infeed Conv. INV InverterLFM Line Filter Module

LFC Line Filter Choke


AFE used for braking - Arguments I

Easy to use braking solution for energy efficient operation

Continuous nominal braking power and overload capability

Sinusoidal mains current in all operating states

Constant Power factor 1 in all operation modes

Mains voltage drops up to 40% without interruption of operation

Standard distribution transformer can be used

Wide mains frequency range (30 -70 Hz)


AFE used for braking - Arguments II

● No additional high temperature heat source like with resistor braking

● Adjustable braking torque and braking power

● Adjustable fast deceleration ramps

● Resistor braking for emergency operation possible

● Integrated RFI filter, class C3

● Mains short circuit power up to 100kA


Braking options overview

0,75 90/110 630/800 kW200/250

Braking Solution

Braking unit + resistor

Network braking unit

Active Front End

Recommendeddepending on application

Available rangedepending on application

2.400


AFE used for harmonic mitigation - Arguments

Easy to use solution for optimum harmonic mitigation

THDi less than 4% in all operating states

Constant Power factor 1 in all operation modes

Mains voltage drops up to 40% without interruption of operation

Integrated RFI filter, class C3

Wide mains frequency range (30 -70 Hz)

Mains short circuit power up to 100kA

Operation at weak mains supply

Operation at diesel generator supply


Harmonic mitigation overview

0,75 90/110 630/800 kW200/250

HarmonicMitigation Solution

Passive filter

Active filter

Multi pulse solution

Recommendeddepending on application

Available rangedepending on application

2.400

Active Front End


Application setup

1 : 1 - Application

One AFE+

One Inverter

“4Q Drive”“LH Drive”

1 : n - Application

One AFE+

several Inverter

“DC – Bus”

n : n - Application

several AFE+

several Inverter

“Parallel AFE”


1 : 1 - Application

One Active Front End for one Inverter● Same size for AIC and INV full power for both energy directions● AIC and inverter are simply connected via +/- terminals


1 : n - Application

One AFE supplies a common dc-busfor several drives:

● One single mains supply for all drives within a machine/process

● Size of AFE for real power consumption only● Total Inverter power can be up to 4 times the

nominal power of the AFE


n : n - Application

AFE can operate in parallel for supply of a common dc-bus:

● Enables process setup● Used for safety reasons

(redundancy)● Used to increase the supply

power of AFE● Used to “standardize” the

size of AFE● Used to reduce numbers of

spare parts


AFE Control concepts

Control of AFE can be done in several ways:

● Auto start

● Control via digital I/Os

● Control via inverter field bus

● Control and monitoring via CANopen or Modbus

● Control and monitoring via field bus (communication bridge)


Energy efficiency, Example

● Container crane hoisting application, 250 kW load,

cycle time 5 min., operation time: 8h/day, 200 days/a

(1 min. lifting, 1 min. lowering, 3 min. handling)

Energy cost: 0,12 €/kWh

Drive investment for resistor braking: 23.000 €

Drive investment for AFE solution: 34.000 €

● Result

Energy consumption with resistor braking: 100.000 kWh / a = 12.000 €

Energy consumption with AFE: 40.000 kWh / a = 4.800 €

Energy and cost savings: 60.000 kWh / a = 7.200 €

Payback time: ~ 1,5 years


● Easy to install● Mains contactor

● 24V control supply

● Charging circuit

● Charging fuses

● Charging circuit breaker

● Charging resistors

● Fan supply for AIC and INV

● High efficiency due to new control structure● No damping resistors

● Reduced losses of LFM

● No voltage sense lines

● Operation independent of phase sequence

Altivar AFE Technical advantages

Integrated in LFM


● Hardware consistency● Same design of AIC and INV

● Same HMI as for ATV61/71

● Reduce projecting and mounting time

● 90% of spare parts are identically

● Easy servicing

● Same quality

● Quality and Delivery convenience● Assembly on the same production line

● Same delivery performance

● Available also in enclosed version

AFE Commercial advantages


● Complete AFE consist of 3 components only● Easy to project● Simple to mount● Reduce time for wiring

● Practically no limits for mains short circuit capability● Minimum mains short circuit capability not required● Maximum mains short circuit capability 100kA

(7 MVA transformer @ 690V)

● Full integration in Engineered Drives offer● Customised solutions● 100% tested functionality● Optimised size● High protection degree

AFE Competitive advantages I


● Novel LFM design without damping resistors● Patent pending● Reduce losses● Reduce components● Increase energy efficiency

● EMC level C3 as standard● All components build in● Easy to project● Reduce installation time● Provides safe operation

● Easy to wire, AIC cables are pre-assembled● Fan supply cable● Control cables

AFE Competitive advantages II


Product certification / specifications

● Product certification● CE marking according to the low voltage directives (73/23/EEC) and to the

EMC directives (89/336/EEC)

● UL and CSA pending

● EMC emission:● Conducted and radiated emissions in accordance to product standard IEC

61800-3 Category C3 (EN 55011-Class A Group 2)

● Harmonic emission:● Compliance to all actual relevant regulations and standards as e.g.:

● IEC 61800-3

● IEEE 519

● ER G5/4-1

( )


400V class - Specification

● Line voltage:380V … 400V +/-10% (-30% for less than 1 min.) for TT-, TN- or IT-mains

440V … 480V +/-10% (-40% for less than 1 min.) for TT-, TN- or IT-mains

● Line frequency:50/60Hz +/-5% (30 to 70Hz time-limited or with separate supply for the fans)

● Nominal DC-link voltage: 650V DC for mains voltage 3AC 380V/400V

720V DC for mains voltage 3AC 440V


● Overload:120% for 60s every 10 minutes

● Protection degree: IP00, enclosed drives: IP23/IP54/IP54SA


690V class - Specification

● Line voltage:500V … 525V +/-10% (-20% for less than 1 min.) for TT-, TN- or IT-mains

600V +/-10% (-30% for less than 1 min.) for TT-, TN- or IT-mains

690V +/-10% (-40% for less than 1 min.) for TT-, TN- or IT-mains

● Line frequency:500V … 525V: 50Hz +/-5%

600V/690V: 50/60Hz +/-5% (30 to 70Hz time-limited)

● Nominal DC-link voltage: 840V DC for mains voltage 3AC 500V/525V

960V DC for mains voltages from 3AC 575/600V


● Overload: 120% for 60s every 10 minutes

● Protection degree: IP00, enclosed drives: IP23/IP54/IP54SA


Name and Ordering

Name: AFE ●●●V ●●●kWDC power: 120 … 860 kW

Voltage range: 400 = 400 … 480V

690 = 500 … 690V

Each AFE consists of 3 mandatory components, which have to be ordered separately:

Name: AIC - ●V●●● VW3 A7 ●●●LFM - ●V●●● VW3 A7 ●●●LFC - ●V●●● VW3 A7 ●●●

DC power: 120 … 860 kW

Voltage range: 4 = 400 … 480V

6 = 500 … 690V


AFE – Altivar allocation 1:1, 400V

INV (Inverter)Powerin kW AFE-Sizes

ATV71 ATV61 CT VT 400V

- ATV61HD90N4D - 90 400V 120kW

ATV71HD90N4D ATV61HC11N4D 90 110 400V 120kW

ATV71HC11N4D ATV61HC13N4D 110 132 400V 145kW


ATV71HC16N4D - 160 - 400V 240kW

- ATV61HC22N4D - 220 400V 240kW



ATV71HC28N4D - 280 - 400V 430kW




CT … constant torque

VT … variable torque


INV (Inverter)Powerin kW AFE-Sizes

ATV71 ATV61 CT VT 690V

ATV71HC11Y ATV61HC13Y 110 132 690V 145kW









AFE – Altivar allocation 1:1, 690V

CT … constant torque

VT … variable torque


References400V AFE-Sizes Components Component-

References

400V 120kW AIC-4V120:LFM-4V120:LFC-4V120:

VW3 A7 250VW3 A7 260VW3 A7 265


VW3 A7 251VW3 A7 261VW3 A7 266


VW3 A7 252VW3 A7 261VW3 A7 266


VW3 A7 253VW3 A7 262VW3 A7 267


VW3 A7 254VW3 A7 262VW3 A7 267


VW3 A7 255VW3 A7 262VW3 A7 267

400V 430kW AIC-4V430:2 x LFM-4V340:2 x LFC-4V340:

VW3 A7 2562 x VW3 A7 2622 x VW3 A7 267


VW3 A7 2572 x VW3 A7 2622 x VW3 A7 267


VW3 A7 2582 x VW3 A7 2622 x VW3 A7 267

690V AFE-Sizes Components Component-References


VW3 A7 270VW3 A7 263VW3 A7 268


VW3 A7 271VW3 A7 263VW3 A7 268


VW3 A7 272VW3 A7 263VW3 A7 268


VW3 A7 273VW3 A7 264VW3 A7 269


VW3 A7 274VW3 A7 264VW3 A7 269


VW3 A7 275VW3 A7 264VW3 A7 269


VW3 A7 2762 x VW3 A7 2642 x VW3 A7 269


VW3 A7 2772 x VW3 A7 2642 x VW3 A7 269


VW3 A7 2782 x VW3 A7 2642 x VW3 A7 269


List of abbreviations

AFE … Active Front End (consists of LFM+LFC+AIC)

LFM … Line Filter Module (part of AFE)

LFC … Line Filter Choke (part of AFE)

AIC … Active Infeed Converter (part of AFE)

INV … Inverter

THD … Total Harmonic Distortion

EMC … Electromagnetic Compatibility

CT … Constant Torque

VT … Variable Torque

NBU … Network braking unit

4Q … 4 quadrant (operation)

LH … Low harmonic


Make the mostof your energy


More technical details …

ATV71-61 Active Front End V2 S09

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