Professional Documents
Culture Documents
ENERGY
CONFERENCE &
WORKSHOP
FEBRUARY 12-14, 2014
Variable Frequency Drive and
Power Quality Workshop
Robin Priestley
Power Control Manager
Rockwell Automation
RULES OF
ENGAGEMENT
Ask the question
We can go deeper into any subject
CRITIQUE SHEET
Be BRUTALLY Honest!
The goal is to make MREC seminars & Robin BETTER!
Please fill out each section while were there
ROBINS DISCLAIMER
Based on today
100% Accurate?
Compiled by Drives Guy
Discussion is technical
Not brand specific
RESOURCES
http://www.ab.com/drives/energy_savings/index.html
http://www.angelfire.com/pa/baconbacon/page2.html
http://www.pupman.com/listarchives/2001/June/msg00679.html
http://www.energysafe.com.au/products.html
http://www.iserv.net/~alexx/lib/general.htm
http://www.myronzuckerinc.com/docs/Specification%20%20Trap%20Filter.pdf
http://www.transcoil.com/
http://www.et-sales.com/K_Factor.html
http://www.ab.com/drives/energy_savings/index.html
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TOOLS
Engineering Assistant
Break/Regeneration Calculator
Harmonics Estimator
Energy Savings Calculator
Allen-Bradley Team
Seminars
DRIVES IN
RURAL
APPLICATIONS
How many can you think of?
HMMMMM?
Irrigation
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AC Input
Rectified to DC
Waveform Smoothed
Chopped into AC
WHAT IS PWM?
Pulse Width Modulation
Pulse Width Modulation is a technique that involves turning an output ON for a period of time, and then OFF
for the balance of the time. This is done without varying the voltage.
When all Pulses have same Width, the output is a square wave.
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WHAT IS PWM?
Short ON times with
Long OFF times result in
lower average voltage.
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WHAT IS PWM?
PARAMETERS AND
PROGRAMMING
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Speed Control
Local Control
(HIM)
Remote Potentiometer
(0-10V)
Analog
(0-10V, 4-20ma)
Preset Speeds
MOPs
Network Control
PROGRAMMABLE
INPUTS
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Control Wiring
CONTROL WIRING
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Control Wiring
CONTROL WIRING
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Stop Modes
Ramp to Stop
Coast To Stop
Ramp to Hold
DC Brake
VFD should not be susceptible to, or create problems with other electrical
equipment operated on the same power distribution circuit.
(V/Hz)
(FVC)
(SVC)
Enhanced V/Hz
Vector Control
Encoderless
Field Oriented
Control
(V/Hz)
V/Hz with slip
comp.
Sensorless Vector
Control
Field Oriented
Control
w/ Encoder Fdbk
Ref
Current
Limit
V/Hz
V mag
Voltage
Control
Slip
Estimator
Slip Frequency
VOLTS/HERTZ CURVE
Base Voltage
Base Frequency
460
Voltage
Frequency
60
Ratio exists between voltage and frequency volts per hertz (V/HZ)
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CUSTOM VOLTS-PER-HERTZ
Base Voltage
Base Frequency
AC Drive Functionality
Maximum Voltage
Maximum Frequency
Voltage
Break Voltage
Break Frequency
Start
Boost
0
Frequency
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AUTO DC BOOST IN
AC Drive Functionality
VOLTS/HZ
Base Voltage
Base Frequency
Voltage
Automatic Selection
Frequency
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4
1
9
1
3
2
8
3
8
2
7
2
3
3
4
4
Output Frequency
2
5
6
5
1
6
6
6
0
7
5
7
Voltage
40.0
Volts/Hertz Ratio
30.0
20.0
Frequency
10.0
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88.6
85.8
83.0
80.2
77.3
74.5
71.7
68.9
66.1
63.3
60.5
57.7
54.8
52.0
49.2
46.4
43.6
40.8
38.0
35.2
32.3
29.5
26.7
23.9
21.1
18.3
15.5
12.7
9.8
7.0
4.2
1.4
0.0
1.5
1.0
.5
16.7
33.3
50
Speed in Hertz
66.7
83.3
SENSORLESS VECTOR
CONTROL
Current Fdbk
Torque Cur
Estimator
V/Hz Control
Inverter
Ref
V mag
Current
Limit
Volt
Vector V ang
Voltage
Control
M
Torque Cur
Estimator
Autotune Parameters
Slip
Estimator
Slip Frequency
V Angle controls the amount of total motor
current that goes into motor flux
250%
MotorNameplate DataEntered = 40 :1
200%
Torque
150%
100%
50%
Output Hertz
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10
0%
Torque
12 5
10
20
30
Speed (Hz)
40
50
60
STARTING TORQUE
Out of the Box = 150%
W/ Motor NP Values = 200%
Optimum Tuning = 250%
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1.5
1.0
.5
10
20
30
40
50
60
Speed in Hertz
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70
80
90
100
Current Fdbk
Ref
Speed
Reg.
Field
Cur. Reg.
Field
Bridge
SCR
Control
Armature
Cur. Reg.
Arm
Bridge
M
PG
Current Fdbk
Voltage Fdbk
Speed Fdbk
Current Fdbk
Ref
Speed
Reg.
V mag
Flux
Reg.
Inverter
Torque
Ref
Current
Reg.
V ang
Voltage
Control
M
PG
Adaptive
Controller
Autotune Para
Slip Frequency
Voltage Fdbk
Speed Fdbk
TORQUE VS SPEED
Flux Vector Drive, 1000:1 motor, Tuned
2.5
2.0
Per Unit
Torque
1.0
0.0
1 3 10
20
30
40
50
60
70
80
90
Cooling
Conveyer
Winch
Auger
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Torque
90
80
Torque
70
60
50
40
Acceptable Region
for Continuous Operation)
30
20
10
0
0
12
18
24
30
36
42
HZ
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48
54
60
66
72
78
84
90
100%
Horsepower
Torque &
Horsepower
100%
Percent of Base Speed
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200%
Torque
consideration
Motor
Torque
Operation
120v, 1phase
200-230v, 1 phase
200-230v, 3 phase
380-480v, 3 phase
500-600v, 3 phase
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200-230v, 3 phase
380-480v, 3 phase
500-600v, 3 phase
(Even if the incoming line voltage is single phase, the
drive output will always be 3 phase. Single phase
motors and Variable Frequency Drives are not designed
to work together.)
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WHAT HORSEPOWER?
Three phase hp to 80,000 hp
Single phase conversion to 40,000 HP
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ENCLOSURE RATING
Panel Mount
IP 20(NEMA Type 1)
Flange Mount
IP 20(NEMA Type 1)
NEMA 4
NEMA 12
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DeviceNet
ControlNet
EtherNetIP
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TROUBLESHOOTING
HELPFUL MANUALS:
User Manuals
Troubleshooting Guides
Installation Instructions
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TROUBLESHOOTING TIPS
Is the problem with the Motor or with the Drive??
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TROUBLESHOOTING TIPS
Is the problem with the Motor or with the Drive??
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TROUBLESHOOTING TIPS
Is there a problem with the Control Wiring or
with the Drive??
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TROUBLESHOOTING TIPS
Is there a problem with Parameter Settings??
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TROUBLESHOOTING TIPS
Overvolt Faults
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TROUBLESHOOTING TIPS
Overvolt Faults caused by Voltage spikes on the
incoming line
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TROUBLESHOOTING TIPS
Overvolt Faults caused by Excess Regenerative Braking
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TROUBLESHOOTING TIPS
Overvolt Faults caused by
Reciprocating Loads
If you are turning a load with uneven weight.
Sometimes the load regenerates on every downward swing of
the rotation.
Process Improvement
Increased Reliability
Energy Savings
Extending Service Life of Existing
Systems
Biggest Missed
Opportunities
Process Trim
Flying Start
Velocity Profiling
Potential
Energy
Savings
Frequency Control
Cycle Converter
Six Step SCR / Drive
PWM GTO Drive
PWM Bipolar Transistor
PWM IGBT Drive
PWM 4th Generation IGBT
1950s
1960s
1970s
1980s
1990s
2000
+2
+1
-1
Bi-Polar
IGBT
The cable between the drive and motor represents a substantial impedance to the
PWM voltage pulses of the drive
Cable impedance is proportional to length
Z0=
Semiconductor Risetime
50 ns
100 ns
1.8
IGBT
200 ns
1.6
400 ns
600 ns
1.4
BJT
1 us
1.2
2 us
1
4 us
1
10
100
Cable Distance [ft]
1000
10000
GTO
1800
LL
/V DC = 3 Per Unit
1600 Volts
1600
1400
1200
1000 Volts
1000
800
600
400
200
0
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
5.5
Time ( m s)
6.0
Corona Testing
Begin Corona
Not Harmful
Extreme Corona
Damaging > 5 - 10pc
Effect of Corona
White Residue
Phase to Phase W/O Separator
Turn to Turn
Drive Typically OL Trip
Output Filters
1204-RWR2
LR filter
KLC filters
The Terminator
AC Drive
Solutions
Allen-Bradley
1329 Inverter Duty
Motor
AC
Motor
AC Drive
1204-RWR2
Reactor
KLC filter
@drive
or
Terminator
1204-TFA1
1204-TFB2
@Motor
Plot 2
Before and after the addition of a 1204-RWR2 & 3.0mhy output reactor
1305 3HP 460V 60HZ No-load
300ft shielded cable
After addition of
1321 output reactor
1140Vpk @ Motor
14ms/rise time
After addition of
1204-RWR2
720Vpk @ Motor
660Vpk @ Inverter
Before addition of
1204-RWR2
1180Vpk @ Motor
660Vpk @ Inverter
Custom Eliminator
CABLE OBSERVATIONS
PVC Cable failures on IGBT drives, the conditions were: 12 awg
- wet , steam, Water based lubricant used,
- PVC cold flow problem
QUESTIONS:
What insulation type is the best for IGBT drives ?
0.045
XLPE,
XHHW-2
Standard Wire
Thickness
0.030
PVC 15 mil Nylon 4 mil,
THHN
0.019
80 00
XLPE
Extreme Corona
XLPE
EXTREME
CIV
y = 2526 x0.290
70 00
60 00
BEGIN
XLPE
50 00
BEGIN
CIV
XLPE Begin
Corona
y = 1255 x0.403
40 00
PVC
BEGIN CIV
30 00
20 00
10
CIV ~ 10 % failures
10 0
4,000
UL 1569 XLPE
BIL Testing @ 600V
3,000
2,000
15 mil
PVC
1,000
20 mil
XLPE
0
Hypot Testing:
.0.1
1
10
100
[Insulation
2 * VRATED( eg.
600V) + Life
1,000 [Years]
VRMS ] ~ 3,110 VPK
Service
~ 3,889 VPK
Capacitive Coupling.
Cable charging current.
Triangular 3 Phase
Power Cable
LINK
C MOD
PHASE A
C MOD
CHASSIS
ALL CURRENTS IG MUST
RETURN HERE OR HERE
ISG1
CSG
GND
ISG
GROUND
WIRE
I SG2
I G RETURN
I GND Can Find Its Way Into CNC, PLC, And Computer Grounds
MOTOR
Fundamental Problem
70 ns
Inverter
output
voltage
LL
Common
Mode
Current
6 MHz
I PEAK
dv
I C
dt
L LINK
+
LEM
+
L LINK
CHASSIS
MOTOR
LEM
GND
Inverter
output
voltage
V LL
Common
Mode
Current
6 MHz
1.5 to
50 us
I PEAK
Current
With
Common
Mode
Chokes
1/3
VL
di
dt
PEAK
Vground Lground
di
dt
Cable Impact on
Input Transformer
A
XO
Ilg
PE
(+)
Vdc
bus
Ilg
Motor Frame
Motor Tach
W
C lg-m
Logic
I
lg
EARTH
GROUND
lg
(-)
Ilg
Common Mode
Current Path
C lg-c
PE
Potential #1
Potential #2
Ilg
Potential #3
Interface Electronics
0-10V, communication,
4-20ma,sensor, interface, etc
Potential # 4
Input Transformer
A
XO
Ilg
I lg
PE
Ilg
Common Mode
EARTH GROUND
Potential 4
Conduit
U
(+)
S
I lg
V
Vdc
bus
T
(-)
I lg
s
t
r
a
p
Motor
C lg-m
PE
Motor PE
GND wire
PE
Current Path
Motor Frame
Ilg
Potential #1
Accidental
Contact of
conduit
Potential #2
I lg
Potential #3
AC Drive
XO
Ilg
I lg
PE
Ilg
V
Vdc
bus
Motor
W
PVC
C lg-m
(-)
I lg
PE
I lg
PE
EARTH GROUND
Potential 4
(+)
Ilg
Potential #1
Additional
Motor PE
GND wire
Potential #2
Potential #3
Cable / Armor
& PVC Jacket AC Drive
Cable / Armor
& PVC Jacket
Motor Frame
R U
Ilg
XO
B
S V
I lg
C
PVC
PVC
PE
PE
EARTH GROUND
Potential 4
C lg-m
T W
PE
HRG or
SOLID GND
Motor
Ilg
Potential #1
Additional
Motor PE
GND wire
Potential #2
Potential #3
10 microseconds / Div
System Grounding
PE - Power Earth Ground
TE - True Earth Ground
1305
1305
Logic
PE
Logic
PE
1336 Plus
Logic
1336 Impact
Logic
PE
PE
Logic
PE
PE Bus
1336 Force
PE Bus
Logic
TE
PE
TE
PE Bus
TE Bus
Ground Potential #1
1-2
ao
I ao
Ground Potential #2
U VW
PE
Noise Current
Return Path
Conduit or
Armor Bond
PLC
R S T
Drive 1
PE
Drive 3
PE
PE Copper Bus
To System Ground
Drive 2
PE
Drive 4
PE
PE
PE
U VW
Common Mode
Current on Green Wire
Drive 1
PLC
PE
Drive 3
PE
All Drives
Input Conduit / Armor
L1, L2, L3, GND
R S T
Drive 2
PE
Drive 4
PE
PE Copper Bus
Optional PE to Structure
Steel if Required
TRAY
ARMOR
CONTINUOS WELDED
ALUMINUM ARMOR
TRAY
ARMOR
PVC
A
B C
A
B C
INTERLOCKED
ARMORED
STANDARD
PVC
PVC
A
B C
A
B C
TRAY CABLE
EUROPEAN
UTILITY
STRANDED
NEUTRAL
MOTOR
FRAME
MODULE
MOTOR
WINDINGS
LOGIC
C
MODULE
CONDUIT
DRIVE FRAME
C
MODULE
MOTOR
FRAME
PE
X INCIDENTAL
CONTACT OF
X CONDUIT TO
BUILDING STEEL
LOGIC
C
MODULE
MOTOR
WINDINGS
DRIVE TOPOLOGIES
6 Pulse
Liquid Cooled
12 Pulse
Air Cooled
18 Pulse
24 Pulse
Active Front End
WHATS HAPPENING
IN DRIVE DESIGN
Better
Faster
Cheaper
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Past
Cm
core
Line
Reactor
AC/DC
EMI
FILTER
Motor
DC/AC
Gate drive
Dynamic
Brake
MARKET ISSUES
& DRIVERS
Line
Reactor
RWR
1-5
hp
SMPS
dc/dc
AB
1204
Insulation Type
1000 Vpk
1200 Vpk
PowerFlex 700
AC/DC
new pre
charge
Lower $
DC/AC
Dynamic
EMI
Brake
Gate drive
Filter
EMI
FILTER
Lower $
SMPS
dc/dc
RWR
1-5 hp
(Maxima)
Motor
Insulation Type
1000 Vpk
1200 Vpk
1600Vpk
1850 Vpk
CE Filter Built In
1992
Transistors &
2nd Gen IGBTs
Duals
1995
1998
2000+
Anew
RETROFIT
CONSIDERATIONS
Now that theyre saving money,
Can I still sleep at night?
122
RETROFIT SEQUENCE
Analysis of Existing and Future Customer
Needs
Analysis of Existing System
Decision on Existing Hardware
Obtaining all Parts to Complete System;
Hardware, Software, Communication
Scheme, Service and Training
123
ANALYSIS OF CURRENT
AND FUTURE NEEDS
Speed and or Torque Regulation Levels
Speed Range
Environment
Communication (Now and Tomorrow)
124
ANALYSIS OF FUTURE
NEEDS
Training
Service
Obsolescence
125
ANALYSIS OF CURRENT
SYSTEM TYPE
Mechanical
Hydraulic
Eddy Current
Rotating DC / MG Sets
DC
AC
126
127
CHARACTERISTICS OF
TYPICAL MECHANICAL DRIVE
Constant Torque from Low Speed to Midpoint
Speed
Constant HP from Midpoint Speed to Full
Speed
Internal Gearbox is the Norm
Typical AC / DC drive is 1-5 times the HP of a
typical Mechanical Drive
128
HYDRAULIC SYSTEM
Must Define Speed / Torque Needs
129
130
REASONS FOR
CHANGING A MG SET
Inability to Get Spare Parts Economically
Reduced Operating Cost under Load
MG Efficiency (Less DC Motor) 72-81%
MG Losses 10-12%
DC Losses .6-.7 %
AC Losses 2.5%
131
MOTOR CONCERNS
Obtain Nameplate Data
132
DRIVE CONCERNS
Torque that is really required
Older Motors could accept greater overload
conditions for longer periods of time
System may be over powered for Application
133
OPERATOR CONCERNS
Sequencing
Reference
134
DC BENEFITS AND
LIMITATIONS
135
DC ASSESSMENT OF
CURRENT HARDWARE
P
E
R
C
E
N
T
STARTING TORQUE
300
BREAKDOWN TORQUE
FULL VOLTAGE
250
PULLUP TORQUE
200
FULL LOAD
TORQUE
150
T
O
R
Q
U
E
100
50
0
0
Speed - RPM
136
1800
1740
rpm
AC BENEFITS AND
LIMITATIONS
Stator & Rotor Epoxy
Coating
Cast Iron
Construction
PLS Bearing
Lubrication System
Anti-static
Polypropylene
Corrosion
Resistant Fan
V-Ring Slinger
Stainless Steel
T-Drains
Cast Iron
Conduit Box
Neoprene Lead
Separator
137
Capacitors
& Drives
A Practical Discussion for the Real
World
Power Factor
What is Power Factor?
Power factor is the ratio between active
power (KW) and total power (KVA)
Active power does work
Reactive power produces an electromagnetic field for inductive loads.
-.7
-.8
-.95
Real Work
Unity
Power Factor
-.7
-.8
-.95
Real Work
Unity
Power Factor
-.7
-.8
-.95
Real Work
Unity
Power Factor
Fundamental Current
Reactive Current
Real Current
Total Current
Harmonic Currents
Fundamental Currents
K Factor
An IEEE method of Rating I2R losses and Survivability
>K=> I2R
Nonlinear loads increase Eddy Current (Apparent)
losses in Transformers
Magnetic Structure is Enhanced
De-Rating Transformers
Increases Available Fault Currents
Decrease Effective Load
High Cost
Capacitor Location?
Metering
Utility
Service
Distribution
Entrance
Infrastructure
MCC
POWER QUALITY
CONSIDERATIONS
A Functional Understanding
REMOVING THE
MYSTERY
Harmonics
HARMONICS: DEFINITIONS
IEEE 519
This guide applies to all types of static power converters used in industrial and commercial power systems. The
problems involved in the harmonic control and reactive compensation of such converters are addressed, and an
application guide is provided. Limits of disturbances to the ac power distribution system that affect other
equipment and communications are recommended. This guide is not intended to cover the effect of radio
frequency interference.
Date of Publication : April 9 1993 Status : Active Page(s): 1 - 112 E-ISBN : 978-0-7381-0915-2 Sponsored by :
IEEE Industry Applications Society INSPEC Accession Number: 4441390 Digital Object Identifier :
10.1109/IEEESTD.1993.114370 Persistent Link: http://ieeexplore.ieee.org/servlet/opac?punumber=2227
More
Year : 1993 Date of Current Version : 06 August 2002 Issue Date : April 9 1993 Related Information : An Errata is
available
Revision of ANSI/IEEE Std 519-1981
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Project Name
End User
Customer
notes
version
Prepared by
Date prepared
email of preparer
Robin Priestley
1/22/2014
rspriestley@ra.rockwell.com
Please note that the information shown here is typical and does not
constitute any guarantee of performance or measurement. Several outside
factors can influence the harmonics measured on a power system, including
other equipment within the plant and other equipment in neighboring plants.
This can include, but is not limited to, drives, varying loads and/or other
factory equipment.
The calculated current and voltage harmonics shown in this report are for
estimation purposes only.
Notes:
PCC is a Point of Common Coupling
A "buffered drive" is one that has a DC Link Choke
A "xfmr" is a transformer
All of the values are recalculated when cell data is entered
050519P
Source
60 Hz
100 feet 1
feet between
utility xfmr
and user xfmr
- OR -
Utility
Transformer
or Generator
750 kVA 1
3.00 %Z 1
12470 Vsec 1
0 Isc 1
- OR at PCC1
750 kVA 1
35 Irated 1
1158 Isc 1
16499.2 L, uH 1
1.3 K-factor
22.2 % Irms total to Irated
22.3 % thermal rating
0.6 Irms harmonics
7.7 Irms fundamental
7.7 Irms total
150.7
0.3
7.9
YES
YES
YES
Isc/Iload
% V(THD)
Limit
% I(TDD)
15.0
IEEE special (3% Vthd)
IEEE general (5%Vthd)
IEEE dedicated (10% Vthd)
PCC2
PCC at user xfmr
User
Transformer
300
5.75
480
0
at PCC2
300
361
6276
117.1
1.3
55.5
55.8
15.7
199.5
200.1
31.5
2.0
7.9
YES
YES
YES
PCC3
PCC at distribution panel
50 feet 2
feet between
user xfmr and
distribution panel
Distribution
Panel
kVA 2
%Z 2
Vsec 2
Isc 2
480 Vsec 3
kVA 2
Irated 2
Isc 2
L, uH 2
K-factor
% Irms total to Irated
% thermal rating
Irms harmonics
Irms fundamental
Irms total
6002 Isc 3
5.3 L, uH 3
Isc/Iload
% V(THD)
Limit
% I(TDD)
8.0
IEEE special (3% Vthd)
IEEE general (5%Vthd)
IEEE dedicated (10% Vthd)
30.1
2.1
7.9
YES
YES
YES
Isc/Iload
% V(THD)
Limit
% I(TDD)
8.0
IEEE special (3% Vthd)
IEEE general (5%Vthd)
IEEE dedicated (10% Vthd)
0 feet to panel
12 pulse buffered drive with iso xfmr
Iso
0 feet to panel
18 pulse buffered drive with auto xfmr
Auto
0 feet to panel
18 pulse buffered drive with iso xfmr
Design Checks: (blank if no issues)
Cell Key:
Iso
data entry
intermediate calc
harmonic results
Before using this for the first time, go to the worksheet tab labeled "Tutorial"
For help and additional information, go to the worksheet tab labeled "Notes & Tools"
0 feet to panel
Custom
0 total hp
100.0 % load
at PCC3
total hp
100.0 % load
50 feet to panel
6 pulse buffered drive without line reactor
PCC1
PCC at utility xfmr
49.5 total hp
100.0 % load
0 total hp
100.0 % load
0 total hp
100.0 % load
0 total hp
100.0 % load
0 total hp
100.0 % load
0 total hp
100.0 % load
0 total hp
100.0 % load
Ifund at FL
100.0 % load
HARMONICS: DEFINITIONS
Fundamental Frequency
Native frequency, cycles per second (CPS), Hertz (Hz)
60 Hz in America, 50Hz in Europe
0
10.00m
20.00m
30.00m
150.0
100.0
40.00m
Rf und.V =...
100.0
50.0
50.0
-50.0
-50.0
-100.0
-100.0
-150.0
0
10.00m
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20.00m
30.00m
-150.0
40.00m
HARMONICS: DEFINITIONS
Harmonics are multiples of the Fundamental Frequency
5th Harmonic is 5 x 60Hz = 300Hz
7th Harmonic is 7 x 60Hz = 420Hz
Full spectrum to 127 th harmonic
Discontinuous Loads
Solid State switching power supplies
Lighting ballasts, computers, variable speed drives
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10.00m
20.00m
30.00m
150.0
100.0
40.00m
Rf und.V =...
100.0
50.0
50.0
-50.0
-50.0
-100.0
-100.0
-150.0
0
10.00m
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20.00m
30.00m
-150.0
40.00m
PRESTO!
YOU NOW HAVE THE CAMELS HUMP
0
10.00m
20.00m
30.00m
150.0
100.0
40.00m
Rf und.V =...
100.0
50.0
50.0
-50.0
-50.0
-100.0
-100.0
-150.0
-150.0
40.00m
10.00m
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20.00m
30.00m
flakey sensors
everything is fine until the drive is turned on
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InstallationThe
Considerations
for
AC
Drives
99% of issues you
Common Mode
&
Capacitive Coupling
Reflected Wave
Grounding
&
Bonding
InstallationThe
Considerations
for
AC
Drives
99% of issues you
Common Mode
&
Capacitive Coupling
Reflected Wave
Grounding
&
Bonding
GROUNDING
CONSIDERATIONS
TODAYS RESEARCH
What would an internet search reveal?
There is only one choice
High Resistance Ground
Transients
Locating Faults
Fault Damage
Personnel Safety
Coordination
First Fault
ROBINS REBUTTAL
Why is the information so consistent?
If HRG increases safety exponentially, why
isnt it mandated?
Why do so many organizations still use:
Ungrounded
FAULT STATISTICS
98% of faults are phase to ground
Detection and response is far more
important than available current
UNGROUNDED
Significant advantages do exist
Safety, production, Limits damage
Requires
Discipline
Consistency
Modification for VFD and some
other systems
UNGROUNDED
Principle Benefits
Low value of current flow and
reliability during a fault (<5 amps is
industry expectation)
Ensures production through first fault
UNGROUNDED
Claims I can not substantiate
Substantial Over Voltages
Sputtering Faults
Produced in Laboratory Tests
HIGH RESISTANCE
GROUND
Lowers incident energy levels
Not enough in most cases
Coordination still required and more
effective
Personnel injury will still occur unless PPE
and other measures are in place and used.
Reduces ground fault current
Modification for VFD and some other systems
HIGH RESISTANCE
GROUND
Clamps ground fault current at lower
level and may change time base
HIGH RESISTANCE
GROUND
Lowers incident energy levels
Eliminates or marginalizes protective
systems
Lightning arrestors
TVSS
Distribution
VFD
HIGH RESISTANCE
GROUND
Lowers incident energy levels
Ultrasonic
Measurement
SCR
DC Drives
Heating
Electron Beams
SOLIDLY (EFFECTIVELY)
GROUNDED
Still preferred by utilities
Eliminates transient voltages that
cause intermittent ground faults
Stabilizes the neutral voltage
Prevents elevation of phase to ground
voltage
Faults are easily located
Can supply line to neutral loads
SOLIDLY (EFFECTIVELY)
GROUNDED
Arc and stray path current
Limited only by the impedances
which are small
Result is a short term fault
SOLIDLY (EFFECTIVELY)
GROUNDED
Arc flash
All shorts cause an arc
Merriam-Webster
GRID OVERVIEW
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IMPORTANCE OF POWER
QUALITY
Power quality events are mostly random
Utility side: Weather, animal / trees hitting
power lines, car accidents, construction,
equipment failure
Facility-side: Starting of large loads motors,
poor electrical connections, Customer
equipment (arc welders)
Impact on production
Shut down equipment: voltage sags with as
little as 80% remaining can impact production
(lights may not blink)
Immediate or long-term damage to sensitive
electrical equipment
0.5
0
0
-0.5
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-70%
-35%
Magnitude - % Remaining
*Source: EPRI
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Magnitude
Duration
Variable Frequency
Drives Review
Safety
Dont sue or call Human Resources
Lock out tag out
Never work on energized circuits
Drive STORES
The DC Voltage.
Section known as:
STORAGE
BUS CAPACITORS
DC BUS
Motor
causes
the up
current
VoltageINDUCTANCE
isAC
a DC
Square
Wave
made
Drives Output? of
wave shape
to of
bevarious
sinusoidal
pulses
widths
DV/DT Spike
What causes it?
Who does it affect?
What are the concerns with cable
distance?
AC Drives Output?
That is the dv/dt
spike.
D (delta) or change
in the Voltage
divided by the
change in Time
dv/dt Spike
All transistors (switching power
semiconductors) create noise
Not brand specific
Standing Wave.
Reactor Attenuation
Time Base
Time Base
Advantages of DC Link
Magnetic Structure is fully developed anytime the
drive is energized.
DC Link is effective regardless of load
Time Base
Time Base
Motor Theory
List major differences between a Good
Inverter rated motor and Premium Efficient
Designs
Multiple motor applications require what
additional components
Insulation testing should be conducted at
what levels
Regulators
Describe the basic differences between
V/Hz and Vector Regulators
Volts per Hertz is a fixed ratio of Voltage to
Frequency
Vector regulators are dynamic. They change
based on load and motor charactoristics
Can be tuned
Too smart for multiple motor applications
Parameters
Describe the Use or Value of:
Programmable relays
Flying Start
PID loops
Sleep Mode
Programmable Relays
What basic functions are programable
How many selections are available
Describe 3 applications where the relays
could be employed
Typical Failures
Energy Savings
Drives have unity power factor
Power factor is the ration of KW to KVA
Remember Work (Torque) to Apparent
(Magnetism)
Affinity Laws
Energy increases with the cube of
Speed
+20%
+10%
Standard
-10%
-25%
Unity PF
Real Work
Billed KWh
Power Factor
+20%
+10%
Standard
-10%
-25%
Unity PF
Real Work
Billed KWh
Power Factor
+20%
+10%
Standard
-10%
-25%
Unity PF
Real Work
Billed KWh
Power Factor
Affinity Law
In Variable Torque Ideal Loads:
Energy Increases exponentially with speed
Energy Consumed = (speed)3
Energy
Consumed
Speed
Consumption
=(Speed
)
reduction
reduction
Robin Priestley
Power Control Manager
rspriestley@ra.rockwell.com
563-343-8862
2014 Robin Priestley & Rockwell Automation
BACKGROUND
Q: Since bearing currents in
rotating machinery have been
documented for at least 90
years, why is this a
contemporary issue?
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BACKGROUND
Q: Since bearing currents in rotating machinery have
been documented for at least 90 years, why is this a
contemporary issue?
A: Modern PWM inverters create both common mode voltages
(CMV) and common mode currents (CMC) which provide new
opportunities for current to flow through rotating bearings
(along with couplings, gears, etc)
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BACKGROUND
While the 90 year old sources of bearing
currents are well understood and
solutions exist, it is important to keep
them in mind to avoid resurrecting them
in trying to solve the challenges brought
on by common mode voltages and
currents.
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BEARING DAMAGE /
FAILURE MECHANISMS
BEARING DAMAGE /
FAILURE MECHANISMS
BEARING DAMAGE /
FAILURE MECHANISMS
Interrupted current causes melting and
re-hardening of the race material,
creating untempered martensite, which is
brittle and prone to fatigue
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BEARING DAMAGE /
FAILURE MECHANISMS
Interrupted current causes melting and re-hardening
of the race material, creating untempered martensite,
which is brittle and prone to fatigue
The normal bearing loads are then capable of breaking off
small pieces of this brittle material
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BEARING DAMAGE /
FAILURE MECHANISMS
If the damaged material does not progress to a fluted pattern
from subsequent running, two other patterns may be seen
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BEARING DAMAGE /
FAILURE MECHANISMS
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BEARING DAMAGE /
FAILURE MECHANISMS
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Shaft
COMMON MODE
VOLTAGE / CURRENT
Modern PWM drives create switching patterns
where instantaneous average voltage to ground
is not zero.
Voltage has a rapid change of magnitude with
respect to time (dV/dt)
COMMON MODE
VOLTAGE / CURRENT
PHASE
VOLTS
CMV
COMMON MODE
VOLTAGE / CURRENT
PHASE
VOLTS
CMV
COMMON MODE
VOLTAGE / CURRENT
PHASE
VOLTS
CMV
COMMON MODE
VOLTAGE / CURRENT
HIGH FREQUENCY CURRENT PATHS
I = C X DV/DT
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VOLTAGE / CURRENT
0.5
0
Stator Winding to
Frame/Shaft
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Discharge
dv/dt Charging
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VOLTAGE / CURRENT
HIGH FREQUENCY END-END
CIRCULATION
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COMMON MODE
VOLTAGE / CURRENT
ROTOR DISCHARGE CURRENT
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PATHS
CAPACITIVE CHARGING OF
ROTOR / BEARING
Stator Winding
Rotor
+
VCM
CSR
CRF
CSF
Frame
Bearing Voltage : Vb =
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Cb
VCM
Bearing
Csr
Csr + Cb + Crf
COMMON MODE
VOLTAGE / CURRENT
ROTOR DISCHARGE CURRENT
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VOLTAGE / CURRENT
0.5
0
Stator Winding to
Frame/Shaft
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Discharge
dv/dt Charging
BEARING CURRENT
SOLUTIONS
Eliminate or reduce common mode voltage
/ current (Drive design issue)
Create best high frequency ground paths
between drive, motor, and load
Electrostatic shielded induction motor
Insulated bearings
Shaft grounding brush
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BEARING CURRENT
SOLUTIONS FARADAY
(ELECTROSTATIC) SHIELD
Add grounded conductive layer between
stator and rotor
Eliminates stator to rotor coupling
Will not eliminate stator winding to frame
coupling
Still need good high frequency ground current path from
motor to drive ground
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FARADAY SHIELD
AND COUPLED EQUIPMENT
BOND STRAP
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BEARING CURRENT
SOLUTIONS
Internal, end-end from magnetic
asymmetry
Insulate opposite drive-end
bearing
Insulate both bearings
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BEARING CURRENT
SOLUTIONS
Shaft Extension Current (stray ground current)
Insulate coupling
Insulate bearings
Bond strap from motor to load
Better low impedance ground in cable from
inverter to motor
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BEARING CURRENT
SOLUTIONS
Discharge of voltage on rotor
Faraday (electrostatic) shield
Shaft brush
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BEARING CURRENT
SOLUTIONS
Precautions
NO opposite drive end shaft brush with
single opposite drive end insulated bearing
Beware of shaft brush option in opposite
drive end encoder
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MEASUREMENTS
(VOLTAGE)
250
V/div
12.5
V/div
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Common
Mode
Voltage
Shaft
Voltage
MEASUREMENTS
(CURRENT) INTERNAL END-END
CIRCULATION
2 A/div
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MEASUREMENTS
(CURRENT)
Common
Mode
Current
2A/div
(both).
Ground
Conductor
Current
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MEASUREMENTS
(CURRENT)
Shaft
Extension
Current
(30 Amp Pulse)
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MEASUREMENTS
Other than internally-sourced circulating
currents, all data is at high frequency
Data tends to be non-repetitive
Oscilloscope triggering technique
strongly influences perceived results
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CONCLUSIONS
Current flow in rotating bearings is not
new
Common mode voltages and currents
from modern inverters can cause current
flow through bearings (plus couplings,
gears, etc)
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CONCLUSIONS
Corrective actions are dependent upon
the particular type of current flow
Transient (high frequency) nature of the
voltages and currents imposes different
requirements than traditional 60 Hz
waveforms
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CONCLUSIONS
Since the sources of the currents as well as
the paths are typically outside the machine
whose bearings are taking the hit, a thorough
understanding of the system is key
Grounding is important, but more in the sense
of point to point (low impedance) bonding
rather than earthing
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COATED / INSULATED
BEARINGS
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CONDUCTIVE GREASE
While the notion of a conductive grease as a solution may sound
appealing, the electrical behavior of bearing lubricants is not as
simple as "insulating" versus "conducting." Both the behavior of
the grease in bulk as well as the behavior of the thin oil film
separating races from rolling elements is strongly dependent on
external influences, including the presence of a voltage. As a
result, the current and voltage characteristics seen in a rotating
bearing are not simply described by a resistive value. In fact, it is
not simply described by a combination of fixed resistors,
capacitors, and other circuit elements. It has a "memory" effect,
based on past applied voltages and current flow, as well as
behaviors that may best be described as "stochastic."
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CONDUCTIVE GREASE
Different greases can have varying electrical
characteristics, based on their chemical composition, but
still would have the "inconsistent" behavior as described
above.
Any proposed grease would obviously need to not
degrade the "normal" properties expected in a bearing.
The conclusion of the points above is that a change to a
grease with different electrical properties is not a solution
to the basic problem of bearing currents (for neither VFD
nor line-fed motors).
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SHAFT VOLTAGE ?
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INVERTER DRIVEN
INDUCTION MOTOR
BEARING CURRENT
SOLUTIONS
QUESTIONS ?