MasterDrives CUVC Frequency Converters

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09.01.2006
DC-AC, 4WD, Long wheel base
RTG-Training, J.Tikka

SIEMENS AC-Drives
Kalmar RTG-Crane movements are done
by AC - motors.
AC - Drives are controlling motor speed
by changing supply frequency.
More frequency = more speed.
Drives are microprocessor controlled
and PLC gives instructions for speed
reference according to operators input.
Speed feedback is fed to drive from
pulse-encoder attached to end of motors.
(Closed-loop control)
Motors are connected by shielded supply
cables to minimize any EMC noise.
Drives used are DC-AC type
(Common DC supply via Converter unit)

SIEMENS DC - AC Drives
Main parts of Frequency Inverter:
Frequency Converter has Three (3) Main
parts.
RECTIFIER:
Rectifies Incoming AC-Power to

External
Rectifier

DC-Link

Inverter

DC-Power. (Tyristor-/Diode Rectifier)

DC-LINK:
Smoothens rectified DC-Power.

Control Unit

(Capacitor Bank)

INVERTER:

CONTROL UNIT:

Converts DC-Power to AC-Power,

Controls Transistor switching and

Frequency is adjustable.

checks that drive works properly.

(CUVC - Card, Control Unit Vector Control)

SIEMENS DC - AC Drives, Hoist Drive

Hoist + Trolley drive:

One drive is controlling
one motor.

+ -

+ -

+ - + Braking Units
2 x 170kW

Trolley

Hoist

(Common Rectifier)

AC
Power
Source

AC to DC Converter unit

Braking
Resistors.
3~
AC-Motor

3~
AC-Motor

Hoist

Trolley

Gantry DS + DOS drive:

One drive is controlling
two motors (parallel).

+ -

+ Gantry Diesel Opposite

Side

(Common Rectifier)

AC
Power
Source

AC to DC Converter unit

Gantry Diesel Side

SIEMENS DC - AC Drives, Gantry DS and DOS

+ - + Braking Units
2 x 170kW

Braking
Resistors.
3~
AC-Motor

3~
AC-Motor

Gantry Diesel Side

3~
AC-Motor

3~
AC-Motor

Gantry Diesel Opposite Side

Block diagram of RTG (AC - AC) application (2wheel drive, short)

Gantry DS, 75 kW
Gantry DOS, 75 kW

SIEMENS DC - AC Drives, 4WD, Acceleration

Acceleration:
Power Flows from supply
through AC-drive to Motor.

+ -+ -

Braking Units

Gantry DOS

+
Gantry DS

(Common Rectifier)

AC
Power
Source

AC to DC Converter unit

2 x 170kW

Braking
Resistors.

3~
AC-Motor
3~
AC-Motor
3~
AC-Motor
3~
AC-Motor

SIEMENS DC - AC Drives, 4WD, Deceleration

When Drive is braking, motor

generates power.
Power Flows from motor through
Inverter to DC-LINK.
Voltage raises at DC-link, until Braking
unit activates and directs excess
power to Braking Resistor.

+ -+ -

3~
AC-Motor
3~
AC-Motor
3~
AC-Motor

DC-Link Voltage > 757 VDC.

DC-Link Voltage Starts raising

Deceleration:

Gantry DOS

+
Gantry DS

(Common Rectifier)

AC
Power
Source

AC to DC Converter unit

Braking Units
2 x 170kW

Braking
Resistors.
When DC-Link Voltage is
over 757 VDC, Braking Unit
Transistors open and Power
flows to Braking Resistors.

3~
AC-Motor

EMC - limiting the noise

EMC stands for "Electromagnetic Compatibility"
and, in accordance with the EMC Law 2(7),
it defines "the capability of a unit to operate
satisfactorily in an electromagnetic environment,
without itself causing electromagnetic
disturbances which would be unacceptable for
other electrical units in this environment".
In principle, this means that units should not
interfere with each other.
A shielded motor cable with a shield connected
at both sides causes the noise current to flow
back to the frequency converter through the
shield.
Although (almost) no voltage drop arises across
impedance Z E for shielded motor cables, the
voltage drop across impedance Z N can
affect other electrical units.
More details: vc332_kompend_kap03_e.pdf

Incoming Three-phase power

Three-phase power
Drives need power to rotate the motor.
(Comes from Diesel Generator unit)
Power is considered single-phase when it is operated
by one voltage source.
Single-phase power is used for small electrical
demands such as found in the home.
Three-phase power is produced by an alternating
current power supply system equivalent to three
voltage sources.
Three-phase power is a continuous series of three
overlapping AC voltages.
Each voltage wave represents a phase and is offset by
120 electrical degrees.
Three-phase power is used where a large quantity of
electrical power is required, such as commercial and
industrial applications.

DC - AC Drive, mode of operation

Incoming AC-Voltage supply is rectified to DCVoltage by Thyristor rectifier unit.
DC link has capacitor bank, which smoothens
rectified DC Voltage.
DC Voltage is then switched to pulses by IGBT
Transistors.
Transistor Inverter stage is giving positive and
negative pulses, that simulate AC voltage.
Each phase needs therefore 2 transistors
(total 6pcs.).
Pulses are PWM modulated (pulse width modulation)
This modulation gives short pulse in beginning of
cycle and longer pulse on middle of cycle, end of
cycle is also short pulse.
Output Voltage is related to area of pulses.
Short (Narrow) pulse -> low Voltage
Long (Wide) pulse
-> higher Voltage
Switching frequency between positive and negative
pulses change output frequency.

AC - Drive, PWM - Pulse Width Modulation

These samples show you how pulses
are made with the Transistor inverter.
Notice that Voltage Increases when
pulses are wider!
When running motor on small speeds
= low frequency, pulses are also given
to both positive and negative cycles to
ensure slow Voltage change.

Magnetism, Magnetic Flux

Coils in AC-motor are
generating a magnetic field.
Sinusoidal supply changes
magnetic field which is also
called as a flux.
Magnetic flux increases when
Voltage level raises.
Magnetic polarity changes
according Sinusoidal Voltage
polarity.

Developing a Rotating Magnetic Field

A rotating magnetic field must be developed in the stator of

an AC motor in order to produce mechanical rotation of the
rotor.
Wire is coiled into loops and placed in slots in the
motor housing.
These loops of wire are referred to as the stator windings.
The following drawing illustrates a three- phase stator.
Phase windings (A, B, and C) are placed 120apart.
In this example, a second set of three-phase windings is
installed.
The number of poles is determined by how many
times a phase winding appears. In this example, each
phase winding appears two times.
This is a two-pole stator.
If each phase winding appeared four times it would be a
four-pole stator.

Magnetic Field
When AC voltage is applied to the stator,
current flows through the windings.
The magnetic field developed in a
phase winding depends on the direction of
current flow through that winding.
The following chart is used here for
explanation only.
It assumes that a positive current flow in the
A1, B1 and C1 windings result in a north pole.

Magnetic Field
It is easier to visualize a magnetic field if a
time is picked when no current is flowing
through one phase.
In the illustration, for example, a time has
been selected during which phase A has no
current flow, phase B has current flow in a
negative direction and phase C has current
flow in a positive direction.
Based on the earlier chart, B1 and C2 are
south poles and B2 and C1 are north poles.
Magnetic lines of flux leave the B2 north
pole and enter the nearest south pole, C2.
Magnetic lines of flux also leave the C1
north pole and enter the nearest south pole,
B1.
A magnetic field results indicated by the
arrow.

Magnetic Field in Rotation

If the field is evaluated at 60

intervals from the starting point,
at point 1, it can be seen that
the field will rotate 60.
At point 1 phase C has no
current flow, phase A has
current flow in a positive
direction and phase B has
current flow in a negative
direction.
Following the same logic as
used for the starting point,
windings A1 and B2 are north
poles and windings A2
and B1 are south poles.
At the end of six such intervals
the magnetic field will
have rotated one full revolution
or 360.

Magnetic Field and Synchronous speed (magnetic field)

Magnetic Field:
The amount of flux lines (Fi) the magnetic field produces is
proportional to the voltage (E) divided by the frequency (F).
Increasing the supply voltage increases the flux of the
magnetic field. Decreasing the frequency increases the flux.

Synchronous speed:
The speed of the rotating magnetic field is referred
to as synchronous speed (NS ). Synchronous
speed is equal to 120 times the frequency (F),
divided by the number of poles (P).
If the applied frequency of the two-pole stator
used in the previous example is 60 hertz,
synchronous speed is 3600 RPM.

SIEMENS DC - AC Drive, Block Diagram

PSU

W2

C/L+ and D/L-

= Incoming Supply (DC)

ZK

= Capacitor bank

WR

= IGBT Transistors (DC -> AC)

U2, V2 and W2

= Outgoing Supply (AC)

PSU

= Power Supply Unit

IVI

= Inverter Value Interface

ABO

= Adapter Board

IGD

= IGBT Gate Driver

= Temperature Sensing

CUVC

= Control Unit Vector Control

PMU

= ParaMeterization Unit

OP1S

= Operation Panel

CBP2

= Communication Board
Profibus

V2
U2

IVI

ABO

ZK

OP1S
CBP2

PMU

LAPTOP

SIEMENS DC - AC Drive, Supply fuses

Supply fuses are located on top of

Inverter drive.
---------------------------------------------------------Balancing Resistor is balancing the
charge of the serial connected
capacitors to prevent uneven charge of
capacitors.
(uneven charge can cause damage for
capacitors)

SIEMENS DC - AC Drive, Capacitor bank

Capacitor bank (Battery) is used for
smoothen the rectified DC-Voltage and
acting as quick resource of sudden
current peaks.
Balancing Resistor is balancing the
charge of the serial connected
capacitors to prevent uneven charge of
capacitors.
(uneven charge can cause damage for
capacitors)

1L+

1L-

SIEMENS DC - AC Drive, PSU - Card

1

13
X 18

X9

X9

= External 24 V DC supply

X 18

= Power supply from incoming

Phases U1 and V1,
+ Cooling Fan Supply

X 70

= Power supply from DC-link

X 250

= Power supply for IGD-Card

1
1
F1

F2

(Only in bigger drives >250kW)

X 258

X 258

= Power supply to IVI card

F1, F2

= Fan supply Fuses

1
1
16

X 250

X 70

Power Supply Unit:

- Provides power supply for all cards

POWER SUPPLY UNIT

- Powered by:
- external 24 V DC supply
- Supply from incoming AC power
- Supply from DC link

SIEMENS DC - AC Drive, IVI - Card

U
11

U
21

U
31

U
12

U
13

U
22

U
23

U
32

U
33

13

14

26

X 205

INVERTER VALUE
INTERFACE

30

X 201

6
X 31

1 2
X 33

7 1
X 41

8
X 43

15
X 208

X 33

= Jumper for 3 CTs on HOIST

(Current transformers)

X 41

= Output Current measurement

(From Current transformers)

X 43

= Multiparallel Connection
(No Connection)

X 201

= ABO Connector

X 204

= Power supply for bigger CTs

(No Connection)

X 205

= IGD Control (Flat cable)

X 206

= Shunt connection -> PCC Card

X 208

= Power Supply from PSU

IGD Control for Bigger Drives >200kW

X 206
3
X 204

= Temperature sensor ( 5V=20 )

**********************************************************************************

X 31

U 11,12

= Firing signals for 1st phase IGBT

U 21,22

= Firing signals for 2nd phase IGBT

U 31,32

= Firing signals for 3rd phase IGBT

U 13,23,33= Feedback Signal from IGD card

SIEMENS DC - AC Drive, IGBT Transistors

Sample picture of IGBT Transistor

DC-Link supply

1L+

1L-

IGD-Card
Controls
IGBT- Transistor
Firing
(PWM Modulation)

E
G

A(e)
K(c)

IGBT = Insulated Gate Bipolar Transistor

PWM Modulated AC ~3 phase out

SIEMENS DC-AC Drive, Components

DC - LINK IN
(From Common Rectifier)

SIEMENS AC-Drive, Semiconductors

Voltage, Power and Torque

T P

U/V

100 %

100 %

TL= T/n

IR
f / Hz

f / Hz
60 Hz

60 Hz

Voltage, Power and Torque of a squirrel Cage motor as a function of the frequency

PC Connection to the drive

DriveMonitor Program

OP1S - Operating Panel

OP1S - Operating Panel, commonly used buttons

Toggle key is used for selecting menu levels

and switching between parameter number,
parameter index and parameter value. The
current level is displayed by the position of the
cursor on the LCD display
(the command comes into effect when the key is released).

Raise key used for increasing the displayed value

Short press = single-step increase
Long press = rapid increase
(If motor potentiometer is active, this is for raising the setpoint).

Lower key used for decreasing the displayed value

Short press = single-step decrease
Long press = rapid decrease
(If motor potentiometer is active, this is for lowering the setpoint).

Reset

Reset key used for leaving menu levels

If fault display active, this is for acknowledging
the fault (resetting).

OP1S - Operating Panel, Controls

PMU - Panel, Controls

PMU - Panel, Commonly used controls

Toggle key is used for selecting menu levels and

switching between parameter number, parameter
index and parameter value. If fault display active,
this is for acknowledging the fault (resetting).
(the command comes into effect when the key is released).

Raise key used for increasing the displayed value

Short press = single-step increase
Long press = rapid increase
(If motor potentiometer is active, this is for raising the setpoint).

Lower key used for decreasing the displayed value

Short press = single-step decrease
Long press = rapid decrease
(If motor potentiometer is active, this is for lowering the setpoint).

I
OP1S/Laptop connection

ON key is used for energizing the drive

(enabling motor activation).
If there is a fault: For returning to fault display
OFF key is used for de-energizing the drive by
means of OFF1, OFF2 or OFF3 (P554 to 560)
depending on parameterization.

Single Quadrant Driving

In the speed-torque chart there are four quadrants according to direction of rotation and
direction of torque. A singlequadrant drive operates only in quadrants I or III (shaded
area). Quadrant I is forward motoring or driving (CW).
Quadrant III is reverse motoring or driving (CCW). Reverse motoring is achieved by
reversing the direction of the rotating magnetic field. Motor torque is developed in the
positive direction to drive the connected load at a desired speed (N).
This is similar to driving a car forward on a flat surface from standstill to a desired
speed.
It takes more forward or motoring torque to
accelerate the car from zero to the desired speed.
Once the car has reached the desired speed your foot
can be let off the accelerator a little.
When the car comes to an incline a little more gas,
controlled by the accelerator, maintains speed.
T = Torque, N = Speed

Four-Quadrant / Dynamic Braking

The dynamics of certain loads may require four-quadrant operation.
Torque will always act to cause the rotor to run towards synchronous speed.
If the synchronous speed is suddenly reduced, negative torque is developed in
the motor. The motor acts like a generator by converting mechanical power from the
shaft into electrical power which is returned to the AC drive.
This is similar to driving a car downhill.
The cars engine will act as a brake.
Braking occurs in quadrants II and IV.
T = Torque, N = Speed