Active Front End

STI - Power Drives September 2009

Active Front End (AFE)

is an option to Altivar ATV61 and ATV71 range
Feedback energy Reduce energy costs

Harmonic mitigation Increase power quality

Schneider Electric - Engineered Drives - Martin Gradner March 2009

Application examples
Downhill conveyors Gantry crane Supply pumps

Escalators Water pump Fans

Schneider Electric - Engineered Drives - Martin Gradner March 2009

Two main fields of application

Regenerative operation
Hoisting Downhill conveyors High inertia and high dynamic applications Test stands Winches

Harmonic mitigation
Weak mains supply Utilization of full transformer power Generator supply Compliance to IEEE 519 Unstable mains conditions
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Schneider Electric - Engineered Drives - Martin Gradner March 2009

AFE some technical basics I

Intelligent Rectifier + Line Filter Inverter IGBT bridge

L1 L2 L3

U V W

t
motor cos j =1

t
generator cos j = -1

Schneider Electric - Engineered Drives - Martin Gradner March 2009

AFE some technical basics II

AFE works like a step up chopper AFE changeover from motor to generator operation shock-free AFE has a sinusoidal mains current AFE always needs line filter components

Schneider Electric - Engineered Drives - Martin Gradner March 2009

Components of the AFE

AFE LFM Line Filter Module LFC Line Filter Choke AIC Active Infeed Converter

LFM Line Filter Module

AIC Active Infeed Conv.

INV Inverter

LFC Line Filter Choke

Schneider Electric - Engineered Drives - Martin Gradner March 2009

AFE used for braking - Arguments I

Easy to use braking solution for energy efficient operation Continuous nominal braking power and overload capability Sinusoidal mains current in all operating states Constant Power factor 1 in all operation modes Mains voltage drops up to 40% without interruption of operation Standard distribution transformer can be used Wide mains frequency range (30 -70 Hz)
Schneider Electric - Engineered Drives - Martin Gradner March 2009

AFE used for braking - Arguments II

No additional high temperature heat source like with resistor braking Adjustable braking torque and braking power Adjustable fast deceleration ramps Resistor braking for emergency operation possible Integrated RFI filter, class C3 Mains short circuit power up to 100kA

Schneider Electric - Engineered Drives - Martin Gradner March 2009

Braking options overview

Braking Solution

Active Front End

Network braking unit Braking unit + resistor
0,75 90/110 200/250 630/800

2.400

kW

Recommended
depending on application

Available range
depending on application

Schneider Electric - Engineered Drives - Martin Gradner March 2009

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AFE used for harmonic mitigation Arguments

Easy to use solution for optimum harmonic mitigation THDi less than 4% in all operating states

Constant Power factor 1 in all operation modes

Mains voltage drops up to 40% without interruption of operation Integrated RFI filter, class C3

Wide mains frequency range (30 -70 Hz)

Mains short circuit power up to 100kA Operation at weak mains supply

Operation at diesel generator supply

Schneider Electric - Engineered Drives - Martin Gradner March 2009

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Harmonic mitigation overview

Harmonic Mitigation Solution

Multi pulse solution Active Front End Active filter Passive filter
0,75 90/110 200/250 630/800

2.400

kW

Recommended
depending on application

Available range
depending on application

Schneider Electric - Engineered Drives - Martin Gradner March 2009

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Application setup

1 : 1 - Application One AFE + One Inverter

1 : n - Application One AFE + several Inverter

n : n - Application several AFE + several Inverter

4Q Drive LH Drive

DC Bus

Parallel AFE

Schneider Electric - Engineered Drives - Martin Gradner March 2009

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1 : 1 - Application
One Active Front End for one Inverter Same size for AIC and INV full power for both energy directions AIC and inverter are simply connected via +/- terminals

Schneider Electric - Engineered Drives - Martin Gradner March 2009

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1 : n - Application

One AFE supplies a common dc-bus for several drives: One single mains supply for all drives within a machine/process Size of AFE for real power consumption only Total Inverter power can be up to 4 times the nominal power of the AFE

Schneider Electric - Engineered Drives - Martin Gradner March 2009

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n : n - Application
AFE can operate in parallel for supply of a common dc-bus: Enables process setup Used for safety reasons (redundancy) Used to increase the supply power of AFE Used to standardize the size of AFE Used to reduce numbers of spare parts

Schneider Electric - Engineered Drives - Martin Gradner March 2009

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AFE Control concepts

Control of AFE can be done in several ways: Auto start Control via digital I/Os Control via inverter field bus Control and monitoring via CANopen or Modbus Control and monitoring via field bus (communication bridge)

Schneider Electric - Engineered Drives - Martin Gradner March 2009

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Energy efficiency, Example

Container crane hoisting application, 250 kW load, cycle time 5 min., operation time: 8h/day, 200 days/a (1 min. lifting, 1 min. lowering, 3 min. handling) Energy cost: 0,12 /kWh Drive investment for resistor braking: Drive investment for AFE solution: 23.000 34.000

Result
Energy consumption with resistor braking: 100.000 kWh / a = 12.000 Energy consumption with AFE: 40.000 kWh / a = 4.800

Energy and cost savings:

Payback time: ~ 1,5 years

60.000 kWh / a = 7.200

Schneider Electric - Engineered Drives - Martin Gradner March 2009

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Altivar AFE Technical advantages

Easy to install
Mains contactor 24V control supply Charging circuit Charging fuses Charging circuit breaker Charging resistors Fan supply for AIC and INV

Integrated in LFM

High efficiency due to new control structure

No damping resistors Reduced losses of LFM No voltage sense lines Operation independent of phase sequence
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Schneider Electric - Engineered Drives - Martin Gradner March 2009

AFE Commercial advantages

Hardware consistency
Same design of AIC and INV Same HMI as for ATV61/71 Reduce projecting and mounting time 90% of spare parts are identically Easy servicing Same quality

Quality and Delivery convenience

Assembly on the same production line Same delivery performance Available also in enclosed version

Schneider Electric - Engineered Drives - Martin Gradner March 2009

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AFE Competitive advantages I

Complete AFE consist of 3 components only
Easy to project Simple to mount Reduce time for wiring

Practically no limits for mains short circuit capability

Minimum mains short circuit capability not required Maximum mains short circuit capability 100kA (7 MVA transformer @ 690V)

Full integration in Engineered Drives offer

Customised solutions 100% tested functionality Optimised size High protection degree

Schneider Electric - Engineered Drives - Martin Gradner March 2009

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AFE Competitive advantages II

Novel LFM design without damping resistors
Patent pending Reduce losses Reduce components Increase energy efficiency

EMC level C3 as standard

All components build in Easy to project Reduce installation time Provides safe operation

Easy to wire, AIC cables are pre-assembled

Fan supply cable Control cables

Schneider Electric - Engineered Drives - Martin Gradner March 2009

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Product certification / specifications

Product certification
CE marking according to the low voltage directives (73/23/EEC) and to the EMC directives (89/336/EEC) UL and CSA pending

EMC emission:
Conducted and radiated emissions in accordance to product standard IEC 61800-3 Category C3 (EN 55011-Class A Group 2)

Harmonic emission:
Compliance to all actual relevant regulations and standards as e.g.: IEC 61800-3 IEEE 519 ER G5/4-1
Schneider Electric - Engineered Drives - Martin Gradner March 2009

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400V class - Specification

Line voltage:
380V 400V +/-10% (-30% for less than 1 min.) for TT-, TN- or IT-mains 440V 480V +/-10% (-40% for less than 1 min.) for TT-, TN- or IT-mains

Line frequency:
50/60Hz +/-5% (30 to 70Hz time-limited or with separate supply for the fans)

Nominal DC-link voltage:

650V DC for mains voltage 3AC 380V/400V 720V DC for mains voltage 3AC 440V 770V DC for mains voltage 3AC 480V

Overload:
120% for 60s every 10 minutes

Protection degree:
IP00, enclosed drives: IP23/IP54/IP54SA

Schneider Electric - Engineered Drives - Martin Gradner March 2009

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690V class - Specification

Line voltage:
500V 525V +/-10% (-20% for less than 1 min.) for TT-, TN- or IT-mains 600V +/-10% (-30% for less than 1 min.) for TT-, TN- or IT-mains 690V +/-10% (-40% for less than 1 min.) for TT-, TN- or IT-mains

Line frequency:
500V 525V: 50Hz +/-5% 600V/690V: 50/60Hz +/-5% (30 to 70Hz time-limited)

Nominal DC-link voltage:

840V DC for mains voltage 3AC 500V/525V 960V DC for mains voltages from 3AC 575/600V 1100V DC for mains voltage 3AC 690V

Overload:
120% for 60s every 10 minutes

Protection degree:
IP00, enclosed drives: IP23/IP54/IP54SA
Schneider Electric - Engineered Drives - Martin Gradner March 2009

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Name and Ordering

Name: DC power: Voltage range:

AFE V kW
120 860 kW 400 = 400 480V 690 = 500 690V

Each AFE consists of 3 mandatory components, which have to be ordered separately: Name:

AIC LFM LFC

- V - V - V

VW3 A7 VW3 A7 VW3 A7

120 860 kW 4 = 400 480V 6 = 500 690V
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DC power: Voltage range:

Schneider Electric - Engineered Drives - Martin Gradner March 2009

AFE Altivar allocation 1:1, 400V

INV (Inverter) ATV71 ATV61 CT Power in kW VT AFE-Sizes 400V

ATV71HD90N4D ATV71HC11N4D ATV71HC13N4D ATV71HC16N4D -

ATV61HD90N4D
ATV61HC11N4D ATV61HC13N4D ATV61HC16N4D ATV61HC22N4D

90 110 132 160 -

90
110 132 160 220

400V 120kW
400V 120kW 400V 145kW 400V 175kW 400V 240kW 400V 240kW

ATV71HC20N4D
ATV71HC25N4D ATV71HC28N4D ATV71HC31N4D ATV71HC40N4D ATV71HC50N4D CT constant torque VT variable torque

ATV61HC25N4D
ATV61HC31N4D ATV61HC40N4D ATV61HC50N4D ATV61HC63N4D

200
250 280 315 400 500

250
315 400 500 630

400V 275kW
400V 340kW 400V 430kW 400V 430kW 400V 540kW 400V 675kW

Schneider Electric - Engineered Drives - Martin Gradner March 2009

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AFE Altivar allocation 1:1, 690V

INV (Inverter) ATV71 ATV71HC11Y ATV71HC13Y ATV71HC16Y ATV71HC20Y ATV71HC25Y ATV71HC31Y ATV71HC40Y ATV71HC50Y ATV61 ATV61HC13Y ATV61HC16Y ATV61HC20Y ATV61HC25Y ATV61HC31Y ATV61HC40Y ATV61HC50Y ATV61HC63Y CT 110 132 160 200 250 315 400 500 Power in kW VT 132 160 200 250 315 400 500 630 AFE-Sizes 690V 690V 145kW 690V 175kW 690V 220kW 690V 275kW 690V 340kW 690V 430kW 690V 540kW 690V 675kW

ATV71HC63Y

ATV61HC80Y

630

800

690V 860kW

CT constant torque VT variable torque

Schneider Electric - Engineered Drives - Martin Gradner March 2009

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References
400V AFE-Sizes 400V 120kW Components AIC-4V120: LFM-4V120: LFC-4V120: AIC-4V145: LFM-4V175: LFC-4V175: ComponentReferences VW3 A7 250 VW3 A7 260 VW3 A7 265 VW3 A7 251 VW3 A7 261 VW3 A7 266 690V AFE-Sizes 690V 145kW Components AIC-6V145: LFM-6V220: LFC-6V220: AIC-6V175: LFM-6V220: LFC-6V220: AIC-6V220: LFM-6V220: LFC-6V220: AIC-6V275: LFM-6V430: LFC-6V430: AIC-6V340: LFM-6V430: LFC-6V430: AIC-6V430: LFM-6V430: LFC-6V430: AIC-6V540: 2 x LFM-6V430: 2 x LFC-6V430: AIC-6V675: 2 x LFM-6V430: 2 x LFC-6V430: AIC-6V860: 2 x LFM-6V430: 2 x LFC-6V430: ComponentReferences VW3 A7 270 VW3 A7 263 VW3 A7 268 VW3 A7 271 VW3 A7 263 VW3 A7 268 VW3 A7 272 VW3 A7 263 VW3 A7 268 VW3 A7 273 VW3 A7 264 VW3 A7 269 VW3 A7 274 VW3 A7 264 VW3 A7 269 VW3 A7 275 VW3 A7 264 VW3 A7 269 VW3 A7 276 2 x VW3 A7 264 2 x VW3 A7 269 VW3 A7 277 2 x VW3 A7 264 2 x VW3 A7 269 VW3 A7 278 2 x VW3 A7 264 2 x VW3 A7 269

400V 145kW

690V 175kW

400V 175kW

AIC-4V175: LFM-4V175: LFC-4V175:

AIC-4V240: LFM-4V340: LFC-4V340: AIC-4V275: LFM-4V340: LFC-4V340:

VW3 A7 252 VW3 A7 261 VW3 A7 266

VW3 A7 253 VW3 A7 262 VW3 A7 267 VW3 A7 254 VW3 A7 262 VW3 A7 267

690V 220kW

400V 240kW

690V 275kW

400V 275kW

690V 340kW

400V 340kW

AIC-4V340: LFM-4V340: LFC-4V340:

AIC-4V430: 2 x LFM-4V340: 2 x LFC-4V340: AIC-4V540: 2 x LFM-4V340: 2 x LFC-4V340:

VW3 A7 255 VW3 A7 262 VW3 A7 267

VW3 A7 256 2 x VW3 A7 262 2 x VW3 A7 267 VW3 A7 257 2 x VW3 A7 262 2 x VW3 A7 267

690V 430kW

400V 430kW

690V 540kW

400V 540kW

690V 675kW

400V 675kW

AIC-4V675: 2 x LFM-4V340: 2 x LFC-4V340:

VW3 A7 258 2 x VW3 A7 262 2 x VW3 A7 267

690V 860kW

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List of abbreviations
AFE LFM LFC AIC INV THD EMC CT VT NBU 4Q LH Active Front End (consists of LFM+LFC+AIC) Line Filter Module (part of AFE) Line Filter Choke (part of AFE) Active Infeed Converter (part of AFE) Inverter Total Harmonic Distortion Electromagnetic Compatibility Constant Torque Variable Torque Network braking unit 4 quadrant (operation) Low harmonic
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Schneider Electric - Engineered Drives - Martin Gradner March 2009

Make the most of your energy

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More technical details

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