Medium Voltage AC Drives - QCFI...

Medium Voltage AC Drives

Hitachi, Ltd.

2Copyright © Hitachi,Ltd.2010 All rights reserved

VFD Technology


Transition of power switching devices

60s

70s

80s

90s

00s

Thyristor based technology

(Current switched devices)

Transistor based technology

(Voltage switched devices)

ThyristorThyristor

GTOGTO

IGCTIGCT

SGCTSGCT

Bipolar TransistorBipolar Transistor

Low voltage IGBTLow voltage IGBT

High voltage IGBTHigh voltage IGBT

IEGTIEGT

Gate Turn Off Thyristor

Integrated Gate

Commutated Thyristor

Symmetrical Gate

Commutated Thyristor

IGBT:

Insulated Gate Bipolar Transistor

Injection Enhanced

Gate Transistor


Main circuit topology

eg) 6,600V x 1.414

=9,332VLine-to-line voltage waveforms

2-Level inverter 3-Level inverter Multi-Level inverter

IM~~~~~~ IM~~~

~~~

IM

~~~~~~

Why Multi-Level Inverter ?

1. Very low voltage spikes →Very low stress for the motors

2. Multi-level + Very high frequency switching of LV-IGBT

→Very smooth sine waveform

3. Proven technology of LV-IGBT→ Very stable operation

4. Combination of LV-VFD technology→ Easy maintenance


Hitachi MV-VFD product lineup

10MVA

4,160

6,600

Output Voltage

[V]

3,300

1,000kVA

7,200

10,000

11,000

100MVA

500 10,000

750 4,450

830 4,890

10M 30M 60M

Air-cooled Multi-Level VFD

HIVECTOL-HVI

Water-cooled

5-Level VFD

HIVECTOL-VSI-H5

(*)

(*): Set parallel

■ Covering broad range of medium voltage drive applications

500 5,000

2,400 360 3,630

630 6,300

Easier maintenance with air-cooled VFD!


Air-cooled

Multi-Level VFD

Inverter Cell

Control PCB

Pre-charge

Resistor

Primary Terminal

Isolation

Transformer

FAN

Isolation Transformer Unit Inverter Unit Control Unit

Secondary Terminal

Over view


Air-cooled

Multi-Level VFD

Main circuit configuration

3.3kV 6.6kV 11kV

IMIM IM

6 cells/phase3 cells/phase

Inverter cell

Each Inverter cell is

simple LV single phase

IGBT PWM inverter!!

3.3kV 6.6kV 11kV

9cells/phase


Air-cooled

Multi-Level VFD

Main power source

6,600V 3φ 50Hz

IM

R

Multi-winding

input isolation

transformer

Inverter

U1 U2 U3 U4 U5 U6

V1 V2 V3 V4 V5 V6

W1 W2 W3 W4 W5 W6

-30°

-20°

-10°

0°

+10°

+20°

Pre-charge source

AC380V ~ 415V

3φ 50Hz

Main circuit configuration

6.6kV

Motor

6.6kV Model

-30°

-20°

-10°

0°

+10°

+20°

-30°

-20°

-10°

0°

+10°

+20°

Control

PCB

PT

PT

CT

CT

Grounding

Detector

Gatepulse


Air-cooled

Multi-Level VFD

Inverter Cell

Full-wave Diode Rectifier

DC-link

Capacitor

Interface

PCB

IGBT

Driver PCB

3-phase

Power input Main Fuse

PCB

Power

Gate pulse

Signals

(Optical Fiber)

Single phase

PWM output

AC 700/460V AC 640/440V

DC link Voltage

945V/620V


❑Total current harmonic distortion < 3%

❑Substantially sinusoidal waveform➔ Low stress for motors

➔ No special thermal and insulation de-rating for motors is required

Output Voltage

Output Current

Output waveform

■No output motor filter is required

Output waveform

Air-cooled

Multi-Level VFD


0

1

2

3

4

5

6

7

8

2 3 4 5 7 11 13 17 19 23 25 29 31 35 37 41 43 47 49

Input harmonics

Air-cooled

Multi-Level VFD

IM

・・・・・

Cell Inverter×18

VCB

(52)

6600V

Analytical value JAPAN METI IEEE-519(20<50)

%Z=4%

2 0.03 3.32 7.00

3 0.01 3.32 7.00

4 0.02 3.32 7.00

5 0.51 3.32 7.00

7 0.95 2.37 7.00

11 0.08 1.52 3.50

13 0.15 1.23 3.50

17 0.01 0.95 2.50

19 0.02 0.85 2.50

23 0.10 0.72 1.00

25 0.04 0.66 1.00

29 0.45 0.66 1.00

31 0.37 0.66 1.00

35 0.34 0.66 0.50

37 0.25 0.66 0.50

41 0.26 0.66 0.50

43 0.13 0.66 0.50

47 0.09 0.66 0.50

49 0.06 0.66 0.50

THD 1.27 - 8.00

Guideline[%]

Individual

Harmonic Order

Analytical value JAPAN METI IEEE-519(20<50)

%Z=4%

2 0.03 3.32 7.00

3 0.01 3.32 7.00

4 0.02 3.32 7.00

5 0.51 3.32 7.00

7 0.95 2.37 7.00

11 0.08 1.52 3.50

13 0.15 1.23 3.50

17 0.01 0.95 2.50

19 0.02 0.85 2.50

23 0.10 0.72 1.00

25 0.04 0.66 1.00

29 0.45 0.66 1.00

31 0.37 0.66 1.00

35 0.34 0.66 0.50

37 0.25 0.66 0.50

41 0.26 0.66 0.50

43 0.13 0.66 0.50

47 0.09 0.66 0.50

49 0.06 0.66 0.50

THD 1.27 - 8.00

Guideline[%]

Individual

Harmonic Order

Input Current Waveform

[%]

➢Input-side Harmonics (In case of 36-pulse model)

IEEE-519-1992IEEE-519-1992Guideline

Suggested byJapan METI

HIVECTOL-HVI

THD (up to 49th) = 1.27%


Specification

Power input

Power output

➢Voltage : AC2,400~11,000V

➢Frequency : 50 Hz (75Hz as option)

Motor control➢Control method : Robust Sensor-less vector control

(Open-loop Vector control)

➢Frequency range : 1~100% of speed

➢Accuracy : +/-0.5% of speed

(+/-0.1% with pulse generator as option)

➢Over load : 110% one minute

Air-cooled

Multi-Level VFD➢Frequency : 50/60 Hz +/-5%

➢Voltage variation ： +/-10% of nominal voltage

Voltage sag : It can continue operation down to 70%

of nominal voltage


Specification

Environment➢Ambient temperature : 0~50 degrees C

-5~50 degrees C for storage

➢Relative humidity : 40~95%

➢Condensation : None

➢Altitude : <1,000m ASL

➢Vibration : <0.98m/s2

➢Dust, Corrosion Gas : None

Protection structure : IP 20 ~ IP42

Standards : IEC, JIS, JEC, JEM

Cooling : Forced air-cooled (Redundant fans as option)

Air-conditioned room is recommended

Air-cooled

Multi-Level VFD

MTBF : >70,000 Hrs

(Mean Time Between Failures)


Specification

Input Insulation Transformer➢Type : Dry type air-cooled multi-winding type

➢Insulation : H class

➢Installation : Integrated in VFD cubicle (In-door)

➢Out-door Oil-filled transformer can be applied as option

Air-cooled

Multi-Level VFD

Output step-up transformer : NOT Required

Input harmonic filter : NOT Required

Output Sine filter : NOT Required

Special Input Switch gear : NOT Required

Special Power Cables : NOT Required

IM

Tr

VCB

(52)


Protection

Heavy faults

Light faults (Alarm)

➢Over current

➢Over voltage

➢Over load

➢Grounding

➢Output AC voltage abnormal

➢Output AC current abnormal ➢Over load warning

➢Speed reference abnormal

➢Motor cooling fan stop

➢Transformer cooling fan stop

➢Transformer panel

temperature high

Air-cooled

Multi-Level VFD

➢Main power input voltage drop

➢Control power supply voltage drop

➢Connectors disconnected

➢Enclosure door open

➢Input transformer secondary earth fault

➢Inverter cell abnormal

➢Inverter panel cooling fan abnormal

➢Motor cooling fan stop & Timer delay

➢Motor abnormal (Thermistor input or RTD(PT100) input)

➢Upstream incoming panel abnormal

➢Enclosure temperature high

➢Input transformer over heat


Digital I/O

DI-0 Inverter stop command

DI-1 Inverter run command

DI-2 Emergency stop

DI-3 Operation interlock

DI-4 Main circuit breaker (52) closed

DI-5

DI-6

DI-7

DO-0 Pre-charging complete

DO-1 Heavy fault

DO-2 Light fault

DO-3 Inverter running

DO-4 Operation interlock ready

DO-5 Main circuit breaker (52) close command

DO-6 Main circuit breaker (52) open command

DO-7

Air-cooled

Multi-Level VFD

Interface

Analogue I/O

AI-0 Speed (Frequency) reference DC 4-20 mA

AO-0 Motor speed (Estimated) DC 4-20 mA

AO-1 Motor current DC 4-20 mA

AO-2 Spare DC 4-20 mA

AO-3 Spare DC 4-20 mA

DI/O, AI/O cards can be added as option.

Communication protocol

➢Device Net

➢Profibus

➢MODBUS


Efficiency

Efficiency: 97% including input transformer loss

Inverter loss : approx. 1 %

Input transformer loss : approx. 2 %

Air-cooled

Multi-Level VFD


Air-cooled

Multi-Level VFD

Patented Pre-Charge Method

Main power supply

Power supplyfor precharging

IM

resistor

Multi-level Drive

DC.C

Inverter Cell

Pre-charging

circuit

Conventional method

of pre-charge

DC Link

Capacitor

Pre-Charge

Resistance

Thyristor

Patented Pre-Charging circuit

Separated pre-charging circuit

Charged by Low voltage power source

No power loss at running operation

Lower parts count makes higher reliability of the VFD

After completed pre-charging of DC-link capacitors,

the pre-charging circuit is disconnected.


Pre-Charging circuit

A(r.m.s.) Excitation inrush current curve

time (c/s)

100ms

200A

190A(peak)　(134A(r.m.s.))

52 breaker closed

Pre-Charge current

Design value

Actual measurement

In case of 6.6kV 3750kVA H-class dry-type transformer

rated current : 328A

The pre-charge function makes excitation

current of input transformer small, too.Design value of inrush current :1256A

Actual inrush current after pre-charge: 134A

(Almost 90% reduction)

Excitation inrush current curve

Air-cooled

Multi-Level VFD


Patented Switching Rotation

Cell U6

Cell U5

Cell U4

Cell U3

Cell U2

Cell U1

+/-6 +/-5 +/-4 …

+/-5 +/-4 +/-3 …

+/-4 +/-3 +/-2 …

+/-3 +/-2 +/-1 …

+/-2 +/-1 +/-6 …

+/-1 +/-6 +/-5 …

+6

+5

+4

+3

+2

+1

0

-1

100% output

80% output

50% outputSw

itch

ing

Lev

el

The lower level cells energize longer and generate heat a lot. On the other hand,

the higher level cells switch frequently and suffer stresses to their gate circuits.

Moreover, some higher level cells do not operate at the low VFD output.

Switching Rotation

Hitachi VFD periodically rotates switching level of each cell so that the stresses of

all cells are leveled. It helps to bring the high reliability.

Hitachi transmission scheme of the switching signal can easily achieve this rotation.


Air-cooled

Multi-Level VFD

Easy Monitoring and Diagnostics

Graphic touch screen

Displays failure status, Reset function available

Operation Screen

Failure Status Display Screen

Cell Inverter Information Screen

Cell Inverter Failure Display Screen

Interlock Display Screen

DI/O Display Screen

Offline Mode Screen

Soft Rev. Display Screen

Controller Malfunction Screen

Item Function

Displays condition and the bar graph of the speed and current

Displays cell inverter and the cell is selectable

Displays failure status of selected cell inverter

Displays incomplete interlock status

Displays input/output condition of contact

Displays offline mode

Displays version information

Displays malfunction occurred in the control system

MalfunctionInterlock Display

I/O StatusOperation Monitoring(Bar Graph)

MalfunctionInterlock Display

I/O StatusOperation Monitoring(Bar Graph)


Graphic touch screen

Operation & monitoring screen Fault message screen Digital I/O screen

Inverter cell selection screen Inverter cell fault message screen

© Hitachi Hi-Rel Power Electronics Pvt. Ltd.. 2014. All rights reserved.

Hitachi Hi-Rel Power Electronics Pvt. Ltd

Hitachi MV VFDs for Cement industry


Wide Range of Product Portfolio

1

Industrial UPS

3Φ Input-1Φ Output System from 10-30 kVA

3Φ Input -3Φ Output System from 10-500 kVA

Battery Charger (Range - 24-360 vDC, up to 1000 A)

Enterprise UPS

Online UPS with 1Φ Input-1Φ Output System from 1-10 kVA

Online UPS with 3Φ Input-1Φ Output System from 10-20 kVA

Online UPS with 3Φ Input-3Φ Output System from 10-300kVA



2

Medium Voltage VFD

Multi level - IGBT Drive, Available up to 14.7 MVA (3.3, 6.6 & 11 kV)

Low Voltage VFD

WJ200 – up to 15KW

SJ700 Low Voltage Inverter (415 V Class, 0.75-450 kW)

Engineered Drive System

For Steel & Process Automation and other Industrial Applications

Industrial Automation & Control

PLC-Micro EHV+/EHV+/Micro EH, SCADA, DCS & Automation Panels



3

Grid Tied Solar Inverters


Serving Entire Gamut of Industries

4


Sanand Manufacturing Works

5

MODELED ON HITACHI’S OMIKA WORKS, JAPAN


Sanand Manufacturing Works

6


PAN India Presence

7

▪ Sales & Service Network across

Major Cities & Industrial Towns in

India

▪ Dedicated & Decentralized 24X7

After-Sales-Service Locations

▪ Technically Equipped Service

Personnel at various Centres with

Spares

▪ Central Spare Stock in Gandhinagar


Key Customers

8

and many others...

Steel & Metal Power Oil & Gas

http://www.google.co.in/imgres?imgurl=http://im.in.com/connect/images/profile/b_profile4/Reliance_Petroleum_300.jpg&imgrefurl=http://connect.in.com/reliance-petroleum/profile-373217.html&h=360&w=300&sz=10&tbnid=Zz1IIxLJ_jvC7M:&tbnh=246&tbnw=205&prev=/images?q=reliance+petroleum+logo&zoom=1&q=reliance+petroleum+logo&hl=en&usg=__vHGpHG4gT6LlOBIOgd2B3sbEe3E=&sa=X&ei=xd4iTdruHcjTrQe4k_DRCw&ved=0CBsQ9QEwAA


Key Customers

9

Cement Others

and many others...

http://www.google.co.in/imgres?imgurl=http://www.fabianpattberg.com/images/logo-lafarge.jpg&imgrefurl=http://www.fabianpattberg.com/tag/csr-reporting/&usg=__8H6tpZN0LUx_HDLBB5-oZYWGe7w=&h=302&w=863&sz=15&hl=en&start=1&sig2=5W5tdlV5GbUm-47agoUotA&zoom=1&um=1&itbs=1&tbnid=kKCq1JfbStzmcM:&tbnh=51&tbnw=145&prev=/images?q=lafarge+logo&um=1&hl=en&tbs=isch:1&ei=rPciTYzBE420rAfO1KXGCw

© Hitachi Hi-Rel Power Electronics Pvt. Ltd. 2015. All rights reserved. 10

Reference List

Sl. No.

Client / Project Site End userMVD rating

(KVA) Motor Rating

(kW)Motor

VoltageApplication Qty

1 ACC Limited ACC Ltd, Lakheri, Rajasthan 1460 1200 6.6 Calciner Fan 1

2 ACC Limited ACC Ltd, Lakheri, Rajasthan 1000 650 6.6 Coal Mill Sep Fan 1

3 ACC Limited ACC Ltd, Chanda, Chandrapur, Maharashtra 500 350 3.3 Cement mill -1 Separator fan 2

4 F L Smidth Pvt Ltd Reliance Cement, Kundangunj, UP 4400 6.6 Bag House Fans 2

5 ACC Limited Lakheri, Rajasthan 2200 1350 6.6 VRM Fan 1

6 Ultratech Cements Ltd Ultratech Cement Ltd, Chittorgarh, Rajasthan 4890 3000 11 Pre-heater Fan 1

7 JK Cement Works JK Cement Chittorgarh Works 600 315 3.3 Bag House Fans 1



10 JK Cement Works JK Cement Mangrol Works. 730 315 6.6 Bag House Fans 1

11 JK Lakshmi Cement Ltd Surat 2200 1250 6.6 Vertical Roller 1

12 JK Lakshmi Cement Ltd Surat 840 600 6.6 CA Fan 1

13 ACC Limited Chanda 800 475 11 BFP 1

14 ACC Limited Chanda 360 250 6.6 BFP 1

15 Ultratech Cements Ltd Sewagram Cement Works, Kutch 2650 1800 6.6 Bag House Fans 1

16 Ultratech Cements Ltd Sewagram Cement Works, Kutch 2650 1800 6.6 Bag House Fans 1

17 Sanghi Cement Sanghi Cement 1450 1050 6.6 Boiler Feed Pump 2

18 Ultratech Cement Ltd Rajashee Cement Works 1090 710 6.6 Fan 1




Reference List

Sl. No.


(KVA) Motor Rating

(kW)Motor



22 Shree Cement Ltd. Shree Cement Raipur Plant 11600 8000 11 Raw Mill 1

23 Shree Cement Ltd. Shree Cement,RAS Site 2900 2400 6.6 Preheater Fan 1

24 Saurashtra Cement Ltd. Saurashtra Cement Ltd., Porbandar 1100 800 3.3 Fan 1

25 Shree Cement Ltd. Shree Cement, Chattisgarh 7060 5400 11 Preheater Fan 1

26 Shree Cement Ltd. Shree Cement, Chattisgarh 5250 1700 11 Kiln Main Drive 1

27 Ultratech Cement Ltd Wanakbori Cement Plant 2900 2350 6.6 Fan 1

28 Ultratech Cement Ltd Hirmi Cement Plant 730 450 6.6 SA Fan 1

29 Ultratech Cement Ltd Awarpur Cement Plant 2650 1850 6.6 Fan 1

30 Ultratech Cement Ltd Ultratech Cement Ltd., Dhar Project 4400 3400 11 Preheater Fan 1

31 Ultratech Cement Ltd Ultratech Cement Ltd., Dhar Project 3625 2800 11 Cement Mill Fan 2

32 Ultratech Cement Ltd Ultratech Cement Ltd., Dhar Project 6550 4700 11 Raw mill Fan 1

33 Loesche India Ltd. Sonapur Raw Project 2200 1500 6.6 Mill Fan 1

34 Shree Cement Ltd. Shree Cement, Rajasthan 3930 3000 6.6 Preheater Fan 2

35 Shree Cement Ltd. Shree Cement Ltd. 3930 3000 6.6 PH Pump 1

36 Shree Cement Ltd. Shree Cement Ltd. 3930 3000 6.6 PH Pump 1

37 Saurashtra Cement Ltd. Saurashtra Cement Ltd., Porbandar 2370 1900 3.3 ID Fan 1

38 Shree Cement Ltd. Karnataka Cement Project. 1410 900 11 Coal mill Fan 1

39 Shree Cement Ltd. Karnataka Cement Project. 1410 950 11 Cooler Fan 1



Reference List

Sl. No.


(KVA) Motor Rating

(kW)Motor



42 Shree Cement Ltd. Karnataka Cement Project. 1410 850 11 Cement Mill Classifier 1

43 Shree Cement Ltd. Bangar Cement Unit . 1410 850 11 Cement Mill Classifier 1

44 Shree Cement Ltd. Karnataka Cement Project. 7060 5400 11 Preheater Fan 1

45 Shree Cement Ltd. Karnataka Cement Project. 2800 1800 11 Raw Mill Bag house Fan 1

46 Shree Cement Ltd. Karnataka Cement Project. 2800 2000 11 Clinker Cooler ESP Fan 1

47 Shree Cement Ltd. Karnataka Cement Project. 2X2800 2X900 11 Kiln Main Drive 1

48 JK Cement Works JK Cement Nimbara works. 1575 1200 3.3 Cooler ID Fan 1

49 ULTRATECH CEMENT LIMITED Birla white 1200 600 6.6 Pre heater Fan 1

50 Humboldt Wedag India Pvt. Ltd. Republic Cement, Bulacan, Phillipines 1145 840 4.16 Raw Mill Bag house Fan 1

51 Humboldt Wedag India Pvt. Ltd. Republic Cement, Bulacan, Phillipines 3140 2600 4.16 Pre-heater Fan 1

52 Humboldt Wedag India pvt. Ltd. Republic Cement, Bulacan, Phillipines 1375 110 4.16 Cement Mill Separator Fan 1

53 Saurashtra Cement Saurashtra Cement 975 750 3.3 Separator Fan 1

54 Shree Cement Ltd. Shree Cement Ltd., RAS 1640 600 6.6 Kiln Main Drive 4

55 JSW Cement JSW Cement, Jajpur 2200 1450 6.6 Roller Press 4

56 Ambuja Cement Ltd. Ambuja Cement Ltd., Bhatapara 1640 1300 6.6 Fan 1

57 Humboldt India Wedag Pvt. Ltd. Iligan Cement, Phillipines 1375 840 4.16 Cement Mill Separator Fan 1

58 Ultratech Cement Ltd. GCW Kovaya 970 560 6.6 Cooler ESP Fan 1

59 Ultratech Cement Ltd. GCW Kovaya 730 450 6.6 Cooler ESP Fan 1

60 Ultratech Cement Ltd. Awarpur Cement works 840 525 6.6 Sepax Fan 1


Reference List

Sl. No.


(KVA) Motor Rating

(kW)Motor


61 JK Cement JK Cement Mangrol 2420 1800 11 Fan 6

62 Birla White Cement Birla White Cement 1200 600 6.6 Pre heater Fan 1

63 Shree Cement Shree Cement 1640 600 6.6 Kiln Main Drive 2

Maximum Rating supplied: 8 MW, 11KV,

for Raw mill application.

Customer: Shree Cements

Medium Voltage AC Drives - QCFI...

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