HIVECTOL-HVI - tudonghoa-iatc. · PDF file2.2 Operating Principle ... (kVA) Output Voltage ......
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Transcript of HIVECTOL-HVI - tudonghoa-iatc. · PDF file2.2 Operating Principle ... (kVA) Output Voltage ......
Copy Right @ Hitachi Ltd.
HIVECTOLHIVECTOL--HVIHVIMedium VoltageMedium Voltage MultiMulti--LebelLebel IGBT Drives IGBT Drives
Introduction0
Copy Right @ Hitachi Ltd.
Contents
1.Product Overview1.1 Introduction1.2 Evolution of Hitachi’s Drive
1.3 HIVECTOL-HVI Features
1.4 Product Lineup
1.5 Target Application
1.6 Drive Cabinet Layout
2.Main Circuit Overview2.1 Circuit Arrangement
2.2 Operating Principle
2.3 Input and Output Waveform
2.4 External Pre-charging Circuit
2.5 Film Capacitor
2.6 Separation Arrangement of Isolation Transformer
2.7 By-pass Circuit to Commercial Power Source
2.8 Separated Wiring
2233 45
789 9
10101111
3.Control Circuit Overview3.1 Sensor-less Vector Control
3.2 Control Board Construction
3.3 Graphic Panel
3.4 Maintenance Tool
3.5 External Interfaces
12
13
14
15
116
4.Drive Selection4.1 Selection Flow Chart
4.2 Drive Capacity Selection
4.3 Energy Savings and CO2 Reduction
5.Data5.1 Dimensional Outline Drawing
5.2 Structural Diagram
5.3 External Interface Terminals
5.4 Specifications
5.5 Options
5.6 Spare parts
5.7 Efficiency Curve To Rotating Speed
5.8 Specification Form for Estimation
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31
34
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Copy Right @ Hitachi Ltd.
1.1 Introduction
Product Overview1
●2007
●2001
●1999
●1995
●1986
●1982
●1973
1.2 Evolution of Hitachi’s DriveHitachi’s Variable Speed Drive Motor history of 75 years started with the DC motor of Ward Leonard. With the evolution of power semiconductors, motor drives have evolved from thyristor to GTO to IGBT systems. Based upon our knowledge and experience from these technologies, we have developed HIVECTOL-HVI as a modern industrial motor drive. We use proven and well accepted IGBT devices for multilevel inverter in a configuration to adapt to industry standard voltages such as 2.4kV, 3.3kV, 4.16kV and 6.6kV.
Hitachi was founded as an electrical repair shop for a mining company and had developed its original 5 HP motors in 1910. For over 90 years since then, Hitachi has established a significant install base of wide range of products. By means of latest motor control technology, Hitachi contributes to improving product quality and to achieving energy saving in many industries such as Iron & Steel, Water Treatment, Chemical Processes, Transportation, and Electrical Power.
30MVA IGBT Drives for steel rolling mills delivered
8MVA HIVECTOL-HVI for utility thermal power plants delivered
Medium Voltage Multi -level IGBT Drives, HIVECTOL-HVI, delivered8MVA
20MVA GTO Drives for steel rolling millsdelivered
Medium Voltage AC Drives for steel rolling mills delivered
DC drive controls, HILECTOL, delivered
The world's first Digital Thyrister Leonard Drives delivered
2 Product Overview
1.3 HIVECTOL-HVI FeaturesHigh Performance
High Reliability High Performance
Multilevel conversion method reduces input side harmonics and conforms to the IEEE519-1992 recommended performance without having to use harmonic filter.
High Function High Flexibility
Series connected IGBT cell inverter controls the output waveform distortion and approximates it to a sine waveform. This reduces stress on the motor insulation and enables trouble free application with the existing motors.
High Reliability Low Loss
Reducing the parts count by patented external pre-charging method.
High Reliability Low Cost
Use of long-life film capacitors in the main circuit reduces maintenance costs.
Space Saving
High Performance High Reliability
Patented control method provides smooth starting and operation with high torque loads and impact loads, without use of a speed feedback sensor.
Installation Flexibility
Separate installation of the transformer cabinet and inverter cabinet is possible.
1.4 Product LineupUser friendly HIVECTOL-HVI-Power/Voltage Map
13.8
11.0
6.6
4.16
3.32.4
Drive Capacity (kVA)
Outp
ut Vo
ltage (
kV)
Air Cooling Type
500 1,000 5,000 10,000 50,000
13.8
11.0
6.6
4.16
3.32.4
Drive Capacity (kVA)
Outp
ut Vo
ltage (
kV)
Air Cooling Type
500 1,000 5,000 10,000 50,000
Torque Charac
3 1.4 Target Application
Product Overview
IndustriesVariable Torque (square law) (Benefit: Energy Saving/CO2 Reduction)
Constant Torque, Constant, Constant Output(Benefit : Flexible and Reliable Production)
Oil & GasFurnace FDF/IDF, Sulfur Recovery BlowerCharge Pump
Large Gas Compressor
ChemicalProcess Fan, Desulfurization Blower,Flux Process Pump, Refrigeration Machine
Polymerization Can, Agitator , Extruder, Cutter, Various type of Compressor
Paper & Pulp Cleaner Pump, Fan Pump, Refiner Paper Machine, Pulper
Ceramic / Earth & RockKiln Air Exhaust Fan, Dust Collection Fan, Cooling Fan, Extractor Fan
Kiln, Crusher , Ball Mill, Vertical Crushing Mill,Grading Machine
Steel / Nonferrous MetalFDF, Furnace Combustion Blower,Dust Exhaust Fan , Descaling Pump
Hoisting Machine, Conveyer
RubberCombustion Air Sending Blower, Feed Pump, Dust Collection Machine
Agitator, Extruder, Conveyer
TextileCombustion Process Blower, Feed Pump,Refrigeration Machines, Dust Collection Machine
Agitator, Extruder, Spinner, Hoisting Machine
Power Generation FDF, IDF, GRF, GMF, BFP Coal Mill, Pulverizing Machine
Food & Beverage Extractor Fan , Air Conditioning Fan Agitator, etc.
Water & Waste Water Water Pump, Waste Water Pump -
Transportation & Logistics Tunnel Ventilation Fan, Wind Tunnel Test Facility -
Machinery Manufacturing Fan Test Facility, Hydraulic PumpTurbine Balance Machine, Test Power Supply Facility
Others Parking Garage Ventilation Fan Others
Common Industry FunctionsBoiler FDF/IDF/GRF/PAF/GMF/BFP,Seawater Pump, Circulation Water Pump
Coal Mill, Petroleum Coke Mill, Biomass Mill
FDF:Forced Draft Fan IDF:Induced Draft Fan GRF:Gas Recirculation FanGMF:Gas Mixture Fan PAF:Primary Air Fan BFP:Boiler Feed Pump
4
HIVECTOL-HVI is composed of “Isolation Transformer”, “Inverter Section” and “Control Unit”.
1.6 Drive Cabinet Layout
Product Overview
Isolation TransformerIsolation Transformer Inverter SectionInverter Section Control UnitControl Unit
●Components inside the control cabinet, such as relay, electronic boards, control power supply and terminal blocks are mounted on the front side. This facilitates easy component replacement and maintenance.
●Inverter cells are mounted in inverter cabinets. The number of cells depend upon the numberof levels & voltage.
●Transformer secondary phase connections are made from the rear side to each cell.
●Each type of control board, fuse, control powersupply is mounted in front of each inverter cell for easy access and maintenance.
●Depending upon the installation space the transformer can be set right next to the inverter.
●Transformer can also be set separately from the inverter. There is a fan on the top of the transformer cabinet.
●Input power can be fed from either top or the bottom.
Isolation Transformer Inverter Section Control Unit
FanPower Source Connector for Fan
Primary Terminal
Secondary Terminal
Main Transformer
Transformer for Control Source Fuse
Precharge ResistorFan
Output BusCell Inverter
Drive Interface Board
Driver Board
Contactor
Fuse
Relay
Circuit Breaker
Terminal BlockControl Board
5 Main Circuit Overview
2.1 Circuit Arrangement
HIVECTOL HVI inverter uses series connected IGBT inverter cells. Each inverter cell is fed from a separate secondary winding. Each inverter cell has a 6 pulse diode rectifier that supplies DC voltage to two level IGBT inverter section. Series connected cell inverters are switched in multiplexed mode and their output step voltages are added to generate a multi-level output voltage that is closer to a sine-wave form.
Medium Voltage Direct InverterHIVECTOL-HVI Series Circuit Arrangement
Isolation Transformer
Inverter Section
Control Circuit
Medium Voltage Direct InverterHIVECTOL-HVI Series Circuit Arrangement
Isolation Transformer
Inverter Section
Control Circuit
The number of inverter cells in a series connection determine the magnitude of the output voltage.
For example, 4 inverter cells connected in series per phase (total 12 units for three phases) will generate 3kV stepped output and 8 inverter cells connected in series per phase will generate 6kV stepped output.
The isolation transformer has multiple phase shifted secondary windings. Viewed from primary side, there is multi-pulse conversion of AC to DC voltage (The number of shifted phase outputs x 2 conversions per cycle). This offers lesser distortion of the voltage waveform at transformer primary.
6 Main Circuit Overview
2.2 Operating Principle
HIVECTOL-HVI is composed of inverter section which connects multiple transformer and cell inverter, and control circuit section which controls switching.Cell inverter consists of three phase input diode converter and two levels IGBT inverter for one phase output. Cell inverter generates DC voltage from three-phase full wave rectification. For example, for 620V DC per one inverter cell will generate 2480V instantaneous, for 4 cells in series. For 3.3kV output voltage, the inverter will have 4 cells x 3 phases = 12 cell inverters. By star connecting these multistage connected inverter cells, line voltage 3,037 volts can be generated. 3.3 kV output is then achieved by adding 3rd harmonic vector offset to the output voltage vector.Cell inverter can output the waveform which is very close to the sine wave because of multilevel addition of voltages and PWM control by IGBT.
Outp
ut Leve
l of
Each D
rive Level 9
Waveform Phase Voltage
Line Voltage Waveform
7 Main Circuit Overview
2.3 Input and Output Waveform
Along with the development of the power electronics, harmonics generated by the frequency converters are being strictly controlled. For a simple 6 pulse rectifier a harmonic suppression filter may be required to limit magnitude of allowable harmonic currents in the supply line. HIVECTOL-HVI series inverters use phase shifted isolation transformers. Typical 18 pulse or higher rectifier operation eliminates need for any harmonic filters on input side. Inverter section connects single phase IGBT PWM inverter cells to generate a output waveform that is very close to the sine wave. Generally this enables operation with existing motors without need for a output filter. Furthermore, the motor noise during operation is also reduced.
IEEE-519-1992Current Distor tion Guideline
LineLine--side current distortion contentside current distortion content
Harmonics
IEEE-519-1992Current Distor tion Guideline
LineLine--side current distortion contentside current distortion content
Harmonics
Curr
ent dis
tortio
n
Output Current
Output Voltage
Output Current
Output Voltage
8 Main Circuit Overview
2.4 External Pre-Charging Circuit
Pre-charging circuit charges the DC capacitor before the input medium voltage breaker is turned on. This is done in order to prevent the inrush current required by capacitor charging when the medium voltage main power supply turns on.HIVECTOL-HVI uses a separate LV power source for pre-charging. This power supply is switched on for about 20 seconds, during which capacitors in the inverter cells charge. Once capacitor charging is completed, the LV supply is disconnected and the medium voltage breaker for main supply is turned on.
Compared to a pre-charging circuit that uses a thyristorswitch and a resistor in each cell unit, the arrangement of separated pre- charging circuit is simple and easy to maintain. This design leads to high reliability in inverter operation. Separated pre-charging circuit method has been patented by Hitachi Ltd (Patent No.3,535,477).
MediumVoltageBreaker
MediumVoltageMain PS
InductionMotor
Pre-charge PS(200V or 400V)
Cell Unit
MultipleTransformer
InverterInverter
Pre-charging Circuit
DCC
Resistor
MediumVoltageBreaker
MediumVoltageMain PS
InductionMotor
Pre-charge PS(200V or 400V)
Cell Unit
MultipleTransformer
InverterInverter
Pre-charging Circuit
DCC
Resistor
9 Main Circuit Overview
Capacitors are used to smooth the DC voltage. These capacitors are usually electrolytic type. However expected life-span of electrolytic capacitors is rather short. This may cause frequent capacitor replacement and result in higher maintenance costs.HIVECTOL-HVI inverter uses film capacitors. This type of capacitor has higher durability and longer life-span.Use of film capacitors drastically reduce the amount of maintenance cost for capacitors.
2.5 Film Capacitor
Film Capacitor
Tenure of Use
Film Capacitor
Electrolytic Capacitor
Running Running CostCostDeviationDeviation
Runnin
g C
ost
Tenure of Use
Film Capacitor
Electrolytic Capacitor
Running Running CostCostDeviationDeviation
Runnin
g C
ost
10 Main Circuit Overview
2.6 Separation Arrangement of Isolation Transformer
While considering installation of inverter in an air conditioned electrical room, the capacity of the air conditioning unit needs to be considered carefully in order to allow proper air-flow and cooling.The inverter isolation transformer needs to be installed in the electrical room, as it generates heat and causes larger capacity air conditioning units to be installed.The multi-winding isolation transformer can be installed separately from the drive cabinet. The separately installed transformer can also be oil filled.This type of installation saves space in electrical room (pre-fabricated or otherwise) and significantly reduces the required air-conditioning capacity for the electrical room.
Air Conditioner
Air Conditioner
ControlUnit
ControlUnit
InverterSection
InverterSection
IsolationTransformer
IsolationTransformer
Electrical Room
Electrical Room
Air Conditioner
Air Conditioner
ControlUnit
ControlUnit
InverterSection
InverterSection
IsolationTransformer
IsolationTransformer
Electrical Room
Electrical Room
11 Main Circuit Overview
2.7 By-pass Circuit to Commercial Power Source
By-pass circuit is useful primarily for two purposes.・Direct Start of Motor In case of maintenance or failure of inverter, the by-pass circuit can start and run the motor on backup mode.・Soft Starting and Stopping of Motor Inverters are used only during starting or stopping of the motor. After the motor starts up, the by-pass curcuit is engaged to commercial power source, allowing the motor and the load to gently start and stop.
By-pass Circuit
Induction Motor
Transformer
Multi-level Inverter
By-pass Circuit
Induction Motor
Transformer
Multi-level Inverter
12 Main Circuit Overview
2.8 Separated Wiring
①Avoid electrical noise from inductive loads and radio noise from power cables and ground cables by separating them.
②If the separation of cables is difficult, then use metallic pipe or metallic board as a shield.③Use shielded twisted pair cable for control and field signals.④Set each grounding wire mutually apart.⑤Prepare the specific grounding for the inverter. ⑥Make sure that minimum size for grounding cable is over 38mm2.
During site installation, signal cables, power cables and grounding cables need to be separated.This helps in avoiding any disturbance to field signals and drive control signals from power circuit. Important reminders are as given below:
Transformer
※EB : Medium Voltage Earth TerminalCB : Low Voltage Earth TerminalE1 : Isolation Transformer Power Cross
Preventing Plate Earth Terminal
A TypeGrounding Electrode
A TypeGrounding Electrode(Less than
10Ω) for Low V Circuit
C TypeGrounding Electrode(Less than
10Ω) for Low V Circuit
B TypeGrounding Electrode(Less than
10Ω) for Low V Circuit
Main CircuitOutput Terminal
Main CircuitInputTerminal
Control UnitInverter Section
Earth Terminal
MainPower Supply
Main CircuitOutput Terminal
Main CircuitInput Terminal
Exist Grounding ElectrodeA Type
Main CircuitInput Terminal
Earth Terminal