Professional Documents
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Beginnings in 1992
ROBICON Perfect Harmony
Product Features and Benefits ROBICON Perfect Harmony Family ROBICON Perfect Harmony Topology Input Power Quality Motor Compatibility High System Availability
The Reasons: Power Quality Legislation The opportunity to retrofit existing motors The ease of system integration
The Solution:
IEEE519 Compliance and PF= .95 or better True sinusoidal Motor Waveform Single lineup includes air components
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Harmony Today
ROBICON Perfect Harmony
Product Features and Benefits ROBICON Perfect Harmony Family ROBICON Perfect Harmony Topology Input Power Quality Motor Compatibility High System Availability System Application & Integration Options
Since Then
Applied to Induction, Wound Rotor, Synchronous, Permanent Magnet and Super-conducting Motors
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Core Features
ROBICON Perfect Harmony
Product Features and Benefits ROBICON Perfect Harmony Family ROBICON Perfect Harmony Topology Input Power Quality Motor Compatibility High System Availability System Application & Integration Options
Superior Availability
All Motor Types and Voltages Supported
Presentation ROBICON Perfect Harmony
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Core Features
ROBICON Perfect Harmony
Product Features and Benefits ROBICON Perfect Harmony Family ROBICON Perfect Harmony Topology
Percent
97.05 97.00 96.95 96.90 96.85 96.80 96.75 96.70 96.65 96.60 96.55 96.50 25 50 Load (Percentage) 75 100
Input Power Quality Motor Compatibility High System Availability System Application & Integration Options
VFD Efficiency
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Inherent Inherent
Included
Inherent
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Factory Integration
Features
Customer Benefits
Fully integrated at
Siemens LD A
In-factory test
Tested as complete systems in our plant Comprehensive proof of performance Enhances reliability by weeding out early
failures
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2008
GenIVe
2007 2006
GenIV & WCIII
2005
NXGII Control
2004
LNG System
2003
2002
Harmony HV - First MV drive to directly run 13.8 kV motors
2001
2000 1999 1998 1997
First IGBT-based drive above 10,000 horsepower (7.5 MW) Next Gen. (NXG) Control with Fast Cell Bypass
Mechanical Cell Bypass: First drive to provide processtransparent, fault tolerant operation
1994 1995
1996
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Air-Cooled
ROBICON Perfect Harmony
Product Features and Benefits ROBICON Perfect Harmony Family ROBICON Perfect Harmony Topology Input Power Quality Motor Compatibility High System Availability System Application & Integration Options
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Water-Cooled
ROBICON Perfect Harmony
Product Features and Benefits ROBICON Perfect Harmony Family ROBICON Perfect Harmony Topology Input Power Quality Motor Compatibility High System Availability System Application & Integration Options
6,000 to 20,000 HP
5 to 15 MW
2300 ~ 7200 V Motors Power Cells 750V, 800 & 1250A
Single bridge to 20,000 HP / 15 MW Four bridges in parallel to 80,000 HP / 60 MW Water to water and water to air HEX options
Presentation ROBICON Perfect Harmony
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High Voltage
ROBICON Perfect Harmony
Product Features and Benefits ROBICON Perfect Harmony Family ROBICON Perfect Harmony Topology Input Power Quality Motor Compatibility High System Availability System Application & Integration Options
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PC-based drive tool provides Windows-based graphical user interface Automatic motor/drive auto-tuning High torque at low speeds w/o encoder
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The following DCS Protocols are supported as standard options from the ROBICON Perfect Harmony VFD system control. Modbus and Modbus Plus Ethernet Modbus Profibus DP DeviceNet ControlNet
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Input voltage Input voltage harmonics (one at a time) Input current Input current harmonics (one at a time) Input PF Input power (kW) Input reactive power (kVAR) Input kW-Hr Input phase sequence Loss of phase Low voltage
Transformer overload Output power (kW) kW-Hr Output current RMS Output voltage RMS VFD efficiency Motor torque Motor speed (RPM) Motor slip (%) Drive output frequency (Hz) Magnetizing current Torque current Motor flux
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A
A3
750 Vac
A2
750 Vac
VAC
A1
750 Vac
VBA
120o
B1
750 Vac
TYP. C1
750 Vac N
B2
750 Vac
C3
750 Vac
B3
750 Vac
VCB
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ROBICON Perfect Harmony Family ROBICON Perfect Harmony Topology Input Power Quality Motor Compatibility High System Availability System Application & Integration Options
A4
750 Vac
A3
750 Vac
A2
750 Vac
VAC
A1
750 Vac
VBA
120o TYP.
B1
750 Vac
C1
750 Vac
C2
750 Vac
B2
750 Vac
C3
750 Vac
C4
750 Vac
B3
750 Vac
B4
750 Vac
C5
750 Vac
B5
750 Vac
B
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VCB robicon-perfect-harmony-theory-e.ppt
A5
1,375 Vac
A4
1,375 Vac
A3
1,375 Vac
A2
1,375 Vac
VAC
VBA
120o TYP. B1
1,375 Vac
A1
1,375 Vac
C1
1,375 Vac
B2
1,375 Vac
C3
1,375 Vac
C4
1,375 Vac
B3
1,375 Vac
B4
1,375 Vac
C5
1,375 Vac
B5
1,375 Vac
C6
1,375 Vac
B6
1,375 Vac
B
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VCB robicon-perfect-harmony-theory-e.ppt
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PH 1375V Cells
PH 750V Cells DIT Primary Winding
7200V
4160V
10,000V
5500V
12,000V
6900V
14,400V
7200Vn+1
If one of the line-ups requires maintenance, it can be disconnected and serviced while the system continues operating.
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Features
Customer Benefits
Clean power
sinusoidal converter
Meets all IEEE 519 1992 requirements No need to do harmonic analysis Eliminates the costly and troublesome
harmonic filters
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Six-Pulse Rectifier
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Actual Test Data Shown 30-Pulse Rectifier Line to Line Voltage 1.2%
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97.05 97.00 96.95 96.90 96.85 96.80 96.75 96.70 96.65 96.60 96.55 96.50 25 50 Load (Percentage) 75 100
Input Power Quality Motor Compatibility High System Availability System Application & Integration Options
VFD Efficiency
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Retrofits?
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Overall induced torque ripple 1% or less on driven load for any given frequency No additional VFD induced motor heating
No dV/dT problems
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Why?
with an order of magnitude smaller voltage steps and a high overall PWM switching frequency
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CELL 2
CELL 3
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With the Harmony Concept the modulation frequency is maintained throughout the motor speed/frequency range.
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For a 3 Series Cell Solution < 0.020 For a 4 Series Cell Solution < 0.010 For a 5 Series Cell Solution < 0.007 For a 6 Series Cell Solution < 0.005
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Motor Voltage
Motor Current
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Wave Forms Remain High Quality at Lower Speeds Due to Multi-level PWM Output
Presentation ROBICON Perfect Harmony
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Motor Current
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Output Harmonics Induced Heating? Motor Operating from Alternator vs. ROBICON Perfect Harmony
Recirc Pump Motor 2B Temperature Rise (based on 3 hour averages)
60
50
40
30 MG Set VFD 20
10
-10 400
500
600
700
800
900
1100
1200
1300
1400
1500
1600
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Output Harmonics Induced Torque Pulsations? Motor Operating from Alternator vs. ROBICON Perfect Harmony cont. Each recirculation pump and motor has a BentleyNevada vibration system Vibration data with M-G set and VFDs compared No impact on vibration levels from VFD operation
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ROBICON Perfect Harmony VFD systems have been applied for solutions where the cable length between the VFD output and motor connection have exceeded 35 kilometers (22 miles). In general, no motor filters are required. When cable lengths exceed 2 kilometers (6,500 feet), a calculation of the output system should be completed to insure that a filter is not required.
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there is any voltage left, continue operating vast majority of power incidents only last a few cycles
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Keeping in mind
100% speed 4.8 kV motor 93% speed* 4 kV motor 100% speed 6 kV motor
90%
90% / 6,248 VII 87.5% / 4,860 VII
80%
The % of available voltage is calculated based on the VFD maximum output voltage, which is larger than the motor rated voltage. A motor operating at a lower voltage can still maintain the required speed by increasing the stator current, which is done automatically by the drive up to the motor/vfd set current limit.
Original Number of Power Cells Per Phase / VFD Output Voltage Available with All Cells Working
*Centrifugal pump/compressor application.
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A2
VAC
C1 C2
A1 120
VBA
B2 B3 B4
B1
Motor Compatibility High System Availability System Application & Integration Options
C5
VCB
A
A3
A2
VAC 132.5
C1 C2 C3 C4
A1
o
132.5
B1
o
VBA
95
B2 B3 B4 B5
C5
VCB
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Bypass Contactor
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8,330
6-6-5
6-6-4, 6-5-5, 5-5-5 6-6-3, 6-5-4, 5-5-4 6-6-2, 6-5-3, 6-4-4, 5-5-3, 5-4-4, 4-4-4 6-6-1, 6-5-2, 6-4-3, 5-5-2, 4-4-3 6-5-1, 6-4-2, 6-3-3, 5-5-1, 5-4-2, 4-4-2, 4-3-3, 3-3-3
7,635
6,942 6,248 5,553 4,860 4,165
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4,860 4,165
3,470 2,777
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ProToPS
ROBICON Perfect Harmony
Product Features and Benefits ROBICON Perfect Harmony Family ROBICON Perfect Harmony Topology Input Power Quality Motor Compatibility High System Availability System Application & Integration Options
Control Strategy
Process protection versus VFD protection Allows the user to decide when and how to respond to an alarm or possible trip situation Provides time for a smooth transition of process Communicates, if required, via a hierarchical service of messages
Alarms
Process Trip
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ProToPS
ROBICON Perfect Harmony
Product Features and Benefits ROBICON Perfect Harmony Family ROBICON Perfect Harmony Topology Input Power Quality Motor Compatibility High System Availability System Application & Integration Options
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Input MV Availability
ROBICON Perfect Harmony
Product Features and Benefits ROBICON Perfect Harmony Family ROBICON Perfect Harmony Topology Input Power Quality Motor Compatibility High System Availability System Application & Integration Options
Input VFD Voltage Within +/- 10% of Rated Value: 100% VFD continuous output power available. Input VFD Voltage Falls Within 90% to 65% of Rated Value: VFD output power is rolled-back linearly from 100% power @ 90% input voltage down to 50% power @ 65% input voltage. During roll-back, the highest available voltage will be sourced to the motor. The output power is reduced by limiting the available motor torque. The VFD can operate continuously in this mode. Input VFD Voltage Falls Below 65% or Disappears All Together: The VFD will ride-through without tripping for at least five cycles. During ride-through the motor voltage is maintained but no torque is produced until input VFD voltage is re-established. If input voltage is not re-established before the energy stored in the power cells is depleted, the VFD will trip.
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Input MV Availability
ROBICON Perfect Harmony
Product Features and Benefits ROBICON Perfect Harmony Family ROBICON Perfect Harmony Topology Input Power Quality Motor Compatibility High System Availability System Application & Integration Options
Available Options
System Element Single Point of Failure None None None None None None None Redundancy Level
Power Electronics VFD Control Cooling Cooling Control VFD Input Filter Motor Filter Output Transformer
N+2 at Rated Power Double Control Requires Second Critical Fault Requires Second Critical Fault Not Required Not Required Not Required
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Transformer Selected Power Cabling Cooling Piping all remaining single points of failure are low FIT
Process Availability Based on a Two-year Breaker-to-Breaker Run
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VFD Sizing
ROBICON Perfect Harmony
Product Features and Benefits ROBICON Perfect Harmony Family ROBICON Perfect Harmony Topology Input Power Quality Motor Compatibility High System Availability System Application & Integration Options
Sizing for Required Current Ratings The first criteria is continuous current rating Gen IV 70, 100, 140, 200 and 260 Amps Gen IIIe 315, 375, 500 and 660 Amps WC III 880 and 1250 Amps HV 500, 800 and 1400 Amps
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VFD Sizing
ROBICON Perfect Harmony
Product Features and Benefits ROBICON Perfect Harmony Family ROBICON Perfect Harmony Topology Input Power Quality Motor Compatibility High System Availability System Application & Integration Options
VFD Sizing
ROBICON Perfect Harmony
Product Features and Benefits ROBICON Perfect Harmony Family ROBICON Perfect Harmony Topology Input Power Quality Motor Compatibility High System Availability System Application & Integration Options
As an Isolation Transformer is always included the input voltage can be set independently from the VFD System output voltage.
Input voltages to 13.8 kV and input frequencies of 50 or 60 Hz are supported in standard designs. Input voltages above 13.8 kV should be referred to the factory for proper sizing. For WCIII and HV solutions, primary voltages above 20 kV require the application of an Air-cooled primary winding. Transformer cubicle sizing may be impacted by the primary voltage rating. Refer to the sizing tables.
Presentation ROBICON Perfect Harmony
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VFD Sizing
ROBICON Perfect Harmony
Product Features and Benefits ROBICON Perfect Harmony Family ROBICON Perfect Harmony Topology Input Power Quality Motor Compatibility High System Availability System Application & Integration Options
Maximum Altitude Without De-rating All Ratings 3300 feet (1000 meters) above 40oC (104oF) and/or 3300 feet (1000 meters) factory must be consulted
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Herriste Coated
Local Disconnect for Each Fan Maximum outside ambient 40OC / 104OF
Presentation ROBICON Perfect Harmony
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Plate Type Heat Exchanger (HEX) 100% Redundant Construction Each HEX Fully Rated Stainless All-welded Construction Integrated Sump Base with Drain Provision Full Isolation Valves In Place Serviceable
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PDC Solutions
ROBICON Perfect Harmony
Product Features and Benefits ROBICON Perfect Harmony Family ROBICON Perfect Harmony Topology Input Power Quality Motor Compatibility High System Availability System Application & Integration Options
A Power Distribution Center (PDC) is commonly supplied as part of a VFD System Solution.
The term PDC is used, as opposed to control house, for tax and depreciation reasons.
For VFD solutions to 10,000 HP (7.5 MW) is common to locate up to two VFDs in a single PDC.
VFD cooling is commonly handled on PDC solutions as follows: GEN IV - Wall Mounted HVAC GEN IIIe Air-to-Air Heat Exchangers WCIII Liquid-to-Air or Water-to-Water Heat Exchangers HV Water-to-Water Heat Exchangers
Note: As more than 96% of all heat is transferred to the heat exchanger. GEN IIIe, WCIII and HV PDCs have very low supplementary HVAC requirements.
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Two doors required for ingress and egress Aisle ways to meet safety and clearance (NEC Common) Walls and ceilings are insulated, floor optional Lighting and emergency lighting Stainless steel door hardware and all external fasteners
Panic Hardware and Automatic Re-closers on Doors Equipment Removal Panel Above Equipment Door Transformer Rear Access Panels for WCIII and HV Systems
Two grounding provisions on PDC base (diagonal sides) Roof slope Walls and ceilings sized for wind, seismic and snow loads Building HVAC N+1 design Low voltage and lighting distribution Included Low voltage feed from distribution to VFD included PDC over-temperature common alarm PDC common fire alarm Optional cable tray with framed openings
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Provision to receive dual low voltage feeds to PDC Automatic transfer switch
Source
Double-conversion UPS
Automatic bypass switch Manual maintenance bypass switch Indication of UPS fault or on battery
to each VFD
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