danfoss - andrew cooper - cii energy conference - chennai ... · nvlt® drive with passive harmonic...
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| Confidential/Property of Danfoss Drives A/S | Tuesday, 07 September 2010 | 1| Confidential/Property of Danfoss Drives A/S | Tuesday, 07 September 2010 | 1
Danfoss
Presenter: Andrew Cooper
Harmonics –Obstructing energy savings
Focused on climate and energy
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Danfoss has solutions ready
nWe have solutions ready for the climate challenge– well-proven technologies with
enormous energy-saving potential
nWe are a global competence centre for energy efficiency– our products and our knowledge are
our key strengths
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Danfoss’ core businessesfocus on Climate & Energy
Power Electronics
n Power modulesn Inverters for Solar & Windn Variable frequency drives
0.18 kW to 1.4 MWn Customized Drive solutions
Refrigeration & A/C Controlsn Mechanical Controlsn Electronic Controlsn Supermarket Servicen Micro Channel Heat
Exchangers
Commercial Compressorsn Commercial Compressorsn Variable Speed Platformsn Turbocor – Joint Venture
Heating Solutions
n Residential Heatingn Electronic Heating Systemsn Hydronic Balancing Controlsn Burner Componentsn Heat Pumpsn Heat Recovery Ventilation
District Energy
n District Energy Controlsn District Energy Stationsn Plate Heat Exchangers
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Customized power modules
n A power module is an electronic switchused in power conversion and motion control applications
n Cutting edge technology designed to meet customer requirements
Generating power from the sunn Danfoss develops, produces and
sells solar inverters that are connected to solar cells
n The inverters ensure that up to 98% of the energy available is supplied to the grid
700,000tons is the annual CO2 reductionsaved by the installation of 80,000 inverters in solar powered systems annually
TS16949standard
meets strict Automotive Industry requirements
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VLT® Drives Electronic motor control
n A variable frequency drive (VFD) controls electric motors so they only run at the speed necessary to obtain the desired effect
n Electronic motor control can typically save half the energy in pump and fan applications
n Today, only 8% of all electric motors globally are frequency controlled
n Productsn VFDsn Soft startersn Accessories
26milliontons is the annual CO2 reduction
made by the 2.4 million Danfoss frequency converters installed worldwide
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Prospective
Source:
U.S. Energy Information Administration / International Energy Outlook 2010
n The expected Energy consumption increase is 2%/years
n Highest increase in non-OECD countriesdue to increasing living standards
n Increased energy demand will lead to increased production.
n Primary source is coal powered power plants
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Climate challenges
n Due to the present climate challenges, more focus has to be put on production of renewable energy
n Energy conservation is very important
n Energy conserving equipments all have same side effect – Harmonic distortion
n Harmonics obstructing further energy savings
Source: The Journal Science: University Corporation for Atmospheric Research
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1~~~
abc
2 3
64 5
IDC
VDC
What are Harmonics?
n All diode rectifier circuits draw non sinusoidal currents
n These are referred to as “non linear” loads
n Biggest contributors are:§ Switch mode power supplies§ Light installations§ UPS§ VFD
n Different VFDs have different current waveforms (harmonic footprint)
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Hz50 250 350 550 650 800 950
%
100
THiD=105%THiD=105%
1st 5th 7th 11th 13th 16th 19th Harmonic
RMS=56ARMS=56A
THiD=0%RMS=39A THiD=78,8%RMS=49A THiD=99,8%RMS=54A THiD=103%RMS=55A
Mathematically harmonics are simply the deviation of a pure sinusoidal waveform.
THiD=105%RMS=56A
What are Harmonics?
n Any periodic signal, independent of shape, can be represented as a sum of sine-waves
n This is called a “Fourier” representation
n Current waveform of a VFD can be also be represented as a sinusoidal waveform sum
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n You can be sure your supply is already polluted with harmonics.
n Current distortion is less important. Voltage distortion is important to restrict
n Product immunity has to be higher than system distortion to prevent breakdown but product life is a function of distortion level.
n Good engineering practice is to design for a THDv of 5% at the in plant point of coupling= class 1 installation
What’s a safe level of Harmonics?
Imm
unity
leve
l
Max
imum
di
stor
tion
leve
l
10%5% 8%
10%8%5%THvD
Class 3Class 2Class 1IEC 61000-2-4
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At the edge of furtherenergy optimization?
n Applying drives is limited to <30-40%of total system loading. Exceeding this level will lead to:n Equipment trips/stopsn Premature equipment agingn Erratic operation and production stop
n To increase load ability special drives with internal or external harmonic filters are needed.
Example of such are:n VLT® 12-pulse Driven VLT® Low Harmonic Drive n VLT® Drive with Passive Harmonic Filtern VLT® AAF (Advanced Active Filter)
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What’s a perfect solution?
n High efficiency
n An equipment that can be turned on/off depending on when needed
n Equipment that does not take up space
n One instead of one each
n Solutions that can also compensate for other grid unfavourable conditions
n Equipment that is reliable
n An easy to use and specify product
n Equipment that can not be overloaded and has long life
n Is free of charge
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What’s a perfect solution?
n Efficiencies of 97% is expected
n Equipment has to be installed in parallel
n Equipment has to be very compact
n One solution to compensate many loads
n Solutions that can also compensate for PF, balance out loads and reduce flicker
n Old technology is better then new
n User-friendly and supporting many different languages
n Equipment that can not be overloaded and has lifetime of 10 years minimum
n Has to be competitive in price
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Technological breakthrough takes you higher
n Danfoss own production of 2nd generation IGBT modules have proven its reliability and shown its boundaries since 2005
n A new and faster digital signal processor in the FC-series has allowed faster and more complex calculations in real time
n New and innovative control algorithm from the market leading engineers have improved harmonic control abilities
n Danfoss is proud to present two new mitigation technologies, taking us closer to the ideal :
n The VLT® Active Filtern The VLT® Low Harmonic Drive
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VLT® Active Filter
n The filter cancels distortion by sensing the harmonic currents and injecting currents in counter phase.
n Easy to install and commission
n Easy to retrofit
n Tolerant to load and grid imbalances
n Allows for group compensation, power factor correction and load balance correction
n Ideal for increasing network capacity or generator power
Active Filter
Active filter c/w
with LCL coil
Non- linear loads. E.G.
6 pulse VFD with DC
bus chokes
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n 190A – 400A ratings (Up to 4 units can be paralleled for higher rating)
n 380 – 480V, 50/60 Hz (Higher voltage with Auto Transformer)
n <5% THD of rated non-linear load I @ PCCn Overall harmonic mitigation up to 40thn Individual harmonic mitigation 5th – 25th &
power factor correction
n Graphical LCP with data logn Energy saving function via sleep moden Compact IP21 & IP54 enclosures with
segregated heatsink back channel coolingn Optional mains isolator & fuse optional.n EMC filters built inn Coated PCB for extra corrosion protectionn ~90% re-use of VLT® Drive components
potentially reduces sparesn Factory load tested
VLT® Active Filter
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n Central compensation
n Group compensation.
n Individual compensation for High Power Drives. (LHD uses AAF active filter)
VLT® Active filter installation / compensation possibilities
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VLT® Active Filters
n The new VLT® Active Filters is installed in parallel and is a flexible choice for compensation of one or multiple loads
n It is built on a 85% drive component reuse ensuring unmatched reliability
n Back-channel cooling reduces electronic contamination and gives prolonged product life
nWith a width of only 600 mm VLT® Active Filters are the most compact solutionavailable
85%Component reuse
ensures unmatched equipment reliability
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VLT® Active Filters
nWith an energy efficiency of 98% the filter is among the most proficient
n The innovative control compensates if needed and goes into sleep if harmonic pollution is low leading to huge energy savings
n Filter offers harmonic compensation, flicker reduction, phase balance, power factor correction and resonance damping
98%Energy efficiency
ensures low running expenses
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VLT® Low Harmonic Driven Optimized active harmonic filter connected in
parallel at input of standard VLT drive in single unit
n 132kW – 630kW, 380 – 480V, 50/60 Hzn Harmonic performance <5% THiDn Meets IEEE519 @ short circuit ratios >20 n >0.98 true power factorn Excellent alternative to active front end
drivesn better performance on weak, pre-distorted
or unbalanced suppliesnmotor friendly (compatible with standard
motors complying with IEC60034-17)n high efficiency
n Energy saving function via sleep moden Drive will run if filter sleeps or trips n Compact IP21 & 54 enclosures with
segregated heatsink back channel cooling n EMC filters built in n Coated PCB for extra corrosion protectionn Factory load tested
Example of CURRENT spec.:Fund. 36.0ATHiD <5.0%RMS current 36.2 A
LHD current wave form
LHD voltage wave form
E- Frame LHD
Active filter c/w
with LCL coil
Standard 6 – pulse
VLT Drive
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VLT® Low Harmonic Drive
n Product efficiency of 97% secures the VLT® Low Harmonic Drive pole position for Active harmonic filtration
n The VLT® Low Harmonic Drive ensures 99% energy utilization in the full load range
n High harmonic mitigation is kept even at distortion levels of more then 10%
n Toughest harmonic standards are meetwith this new series of drives
n Compared to other active mitigation solutions the Danfoss LHD is a motor friendly solution. It does not increase insulation and bearing stress like other active mitigation solutions
99%Energy utilazation
The VLT® Low Harmonic Drive keeps true PF close to 1 independent on grid and load conditions
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The Danfoss LHD is the first of its kind. It combines the best of three technologies, -the simplicity of the AFE, the performance of an Active filter and drive robustness as a standard 6-pulse diode rectifier drive.
Danfoss LHD´s are:n Easy to specify and installn Comply with toughest harmonic standardsn Load and grid independentn Compactn Efficient and motor friendly
Technology is perfect for:n Getting best performance in very week gridsn Systems with high load dynamicn Critical process application
VLT® Low Harmonic Drive
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Danfoss Harmonic portfolio
Advanced harmonic filters:n Lowest cost for >300kwn Most compact solution for
drives <400An Individual matched for Danfoss
drives to secure performancen Capacitor disconnect optionn Better performance then pulse
drives
12P-drives:n Robust and compact solutionn Offers same advantages as our
High power drives.n Lowest cost >400A
Active Filtersn First Active Filter reusing 85%
drive components which secures unmatched reliability and short lead time
n User friendly and easy commissioning
n Flexible in mounting and setupn Fast enough to reduce flicker
Low harmonic Drivesn First of its kind, to include std
drive and an active filter in one package
n Best harmonic mitigationn Motor friendly n High efficiency
Cen
tral mitig
ation /R
etofit
One o
n o
ne
Passive solutionsActive solutions
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VLT® Harmonic Calculation Tool MCT 31n Stand alone mains harmonic calculation
tooln Explorer like project viewn Easy VSD model based selectionn Detailed harmonic report generationn User customized report configuration
Support Tools
PC Software Tool
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We are ready to offer:
n Knowledge and advice about drives and secondary effects
n Freeware calculation tools
n Prompt delivery and support from skilled technicians and sales engineers globally
n A wide harmonic mitigation portfolio of reliable and innovative products. Our high quality product range includes:
n Low Harmonic Drives (A new trendsetter)
n Active Filter (Innovative thinking)
n Passive harmonic filters (Smallest of its kind)
n 12P-drives (A low cost alternative)
Danfoss Drives