Medium Voltage AC Drives
Hitachi, Ltd.
2Copyright © Hitachi,Ltd.2010 All rights reserved
VFD Technology
3Copyright © Hitachi,Ltd.2010 All rights reserved
Transition of power switching devices
60s
70s
80s
90s
00s
Thyristor based technology
(Current switched devices)
Transistor based technology
(Voltage switched devices)
ThyristorThyristor
GTOGTO
IGCTIGCT
SGCTSGCT
Bipolar TransistorBipolar Transistor
Low voltage IGBTLow voltage IGBT
High voltage IGBTHigh voltage IGBT
IEGTIEGT
Gate Turn Off Thyristor
Integrated Gate
Commutated Thyristor
Symmetrical Gate
Commutated Thyristor
IGBT:
Insulated Gate Bipolar Transistor
Injection Enhanced
Gate Transistor
4Copyright © Hitachi,Ltd.2010 All rights reserved
Main circuit topology
eg) 6,600V x 1.414
=9,332VLine-to-line voltage waveforms
2-Level inverter 3-Level inverter Multi-Level inverter
IM~~~~~~ IM~~~
~~~
IM
~~~~~~
Why Multi-Level Inverter ?
1. Very low voltage spikes →Very low stress for the motors
2. Multi-level + Very high frequency switching of LV-IGBT
→Very smooth sine waveform
3. Proven technology of LV-IGBT→ Very stable operation
4. Combination of LV-VFD technology→ Easy maintenance
5Copyright © Hitachi,Ltd.2010 All rights reserved
Hitachi MV-VFD product lineup
10MVA
4,160
6,600
Output Voltage
[V]
3,300
1,000kVA
7,200
10,000
11,000
100MVA
500 10,000
750 4,450
830 4,890
10M 30M 60M
Air-cooled Multi-Level VFD
HIVECTOL-HVI
Water-cooled
5-Level VFD
HIVECTOL-VSI-H5
(*)
(*): Set parallel
■ Covering broad range of medium voltage drive applications
500 5,000
2,400 360 3,630
630 6,300
Easier maintenance with air-cooled VFD!
6Copyright © Hitachi,Ltd.2010 All rights reserved
Air-cooled
Multi-Level VFD
Inverter Cell
Control PCB
Pre-charge
Resistor
Primary Terminal
Isolation
Transformer
FAN
Isolation Transformer Unit Inverter Unit Control Unit
Secondary Terminal
Over view
7Copyright © Hitachi,Ltd.2010 All rights reserved
Air-cooled
Multi-Level VFD
Main circuit configuration
3.3kV 6.6kV 11kV
IMIM IM
6 cells/phase3 cells/phase
Inverter cell
Each Inverter cell is
simple LV single phase
IGBT PWM inverter!!
3.3kV 6.6kV 11kV
9cells/phase
8Copyright © Hitachi,Ltd.2010 All rights reserved
Air-cooled
Multi-Level VFD
Main power source
6,600V 3φ 50Hz
IM
R
Multi-winding
input isolation
transformer
Inverter
U1 U2 U3 U4 U5 U6
V1 V2 V3 V4 V5 V6
W1 W2 W3 W4 W5 W6
-30°
-20°
-10°
0°
+10°
+20°
Pre-charge source
AC380V ~ 415V
3φ 50Hz
Main circuit configuration
6.6kV
Motor
6.6kV Model
-30°
-20°
-10°
0°
+10°
+20°
-30°
-20°
-10°
0°
+10°
+20°
Control
PCB
PT
PT
CT
CT
Grounding
Detector
Gatepulse
9Copyright © Hitachi,Ltd.2010 All rights reserved
Air-cooled
Multi-Level VFD
Inverter Cell
Full-wave Diode Rectifier
DC-link
Capacitor
Interface
PCB
IGBT
Driver PCB
3-phase
Power input Main Fuse
PCB
Power
Gate pulse
Signals
(Optical Fiber)
Single phase
PWM output
AC 700/460V AC 640/440V
DC link Voltage
945V/620V
10Copyright © Hitachi,Ltd.2010 All rights reserved
❑Total current harmonic distortion < 3%
❑Substantially sinusoidal waveform➔ Low stress for motors
➔ No special thermal and insulation de-rating for motors is required
Output Voltage
Output Current
Output waveform
■No output motor filter is required
Output waveform
Air-cooled
Multi-Level VFD
11Copyright © Hitachi,Ltd.2010 All rights reserved
0
1
2
3
4
5
6
7
8
2 3 4 5 7 11 13 17 19 23 25 29 31 35 37 41 43 47 49
Input harmonics
Air-cooled
Multi-Level VFD
IM
・・・・・
Cell Inverter×18
VCB
(52)
6600V
Analytical value JAPAN METI IEEE-519(20<50)
%Z=4%
2 0.03 3.32 7.00
3 0.01 3.32 7.00
4 0.02 3.32 7.00
5 0.51 3.32 7.00
7 0.95 2.37 7.00
11 0.08 1.52 3.50
13 0.15 1.23 3.50
17 0.01 0.95 2.50
19 0.02 0.85 2.50
23 0.10 0.72 1.00
25 0.04 0.66 1.00
29 0.45 0.66 1.00
31 0.37 0.66 1.00
35 0.34 0.66 0.50
37 0.25 0.66 0.50
41 0.26 0.66 0.50
43 0.13 0.66 0.50
47 0.09 0.66 0.50
49 0.06 0.66 0.50
THD 1.27 - 8.00
Guideline[%]
Individual
Harmonic Order
Analytical value JAPAN METI IEEE-519(20<50)
%Z=4%
2 0.03 3.32 7.00
3 0.01 3.32 7.00
4 0.02 3.32 7.00
5 0.51 3.32 7.00
7 0.95 2.37 7.00
11 0.08 1.52 3.50
13 0.15 1.23 3.50
17 0.01 0.95 2.50
19 0.02 0.85 2.50
23 0.10 0.72 1.00
25 0.04 0.66 1.00
29 0.45 0.66 1.00
31 0.37 0.66 1.00
35 0.34 0.66 0.50
37 0.25 0.66 0.50
41 0.26 0.66 0.50
43 0.13 0.66 0.50
47 0.09 0.66 0.50
49 0.06 0.66 0.50
THD 1.27 - 8.00
Guideline[%]
Individual
Harmonic Order
Input Current Waveform
[%]
➢Input-side Harmonics (In case of 36-pulse model)
IEEE-519-1992IEEE-519-1992Guideline
Suggested byJapan METI
HIVECTOL-HVI
THD (up to 49th) = 1.27%
12Copyright © Hitachi,Ltd.2010 All rights reserved
Specification
Power input
Power output
➢Voltage : AC2,400~11,000V
➢Frequency : 50 Hz (75Hz as option)
Motor control➢Control method : Robust Sensor-less vector control
(Open-loop Vector control)
➢Frequency range : 1~100% of speed
➢Accuracy : +/-0.5% of speed
(+/-0.1% with pulse generator as option)
➢Over load : 110% one minute
Air-cooled
Multi-Level VFD➢Frequency : 50/60 Hz +/-5%
➢Voltage variation : +/-10% of nominal voltage
Voltage sag : It can continue operation down to 70%
of nominal voltage
13Copyright © Hitachi,Ltd.2010 All rights reserved
Specification
Environment➢Ambient temperature : 0~50 degrees C
-5~50 degrees C for storage
➢Relative humidity : 40~95%
➢Condensation : None
➢Altitude : <1,000m ASL
➢Vibration : <0.98m/s2
➢Dust, Corrosion Gas : None
Protection structure : IP 20 ~ IP42
Standards : IEC, JIS, JEC, JEM
Cooling : Forced air-cooled (Redundant fans as option)
Air-conditioned room is recommended
Air-cooled
Multi-Level VFD
MTBF : >70,000 Hrs
(Mean Time Between Failures)
14Copyright © Hitachi,Ltd.2010 All rights reserved
Specification
Input Insulation Transformer➢Type : Dry type air-cooled multi-winding type
➢Insulation : H class
➢Installation : Integrated in VFD cubicle (In-door)
➢Out-door Oil-filled transformer can be applied as option
Air-cooled
Multi-Level VFD
Output step-up transformer : NOT Required
Input harmonic filter : NOT Required
Output Sine filter : NOT Required
Special Input Switch gear : NOT Required
Special Power Cables : NOT Required
IM
Tr
VCB
(52)
15Copyright © Hitachi,Ltd.2010 All rights reserved
Protection
Heavy faults
Light faults (Alarm)
➢Over current
➢Over voltage
➢Over load
➢Grounding
➢Output AC voltage abnormal
➢Output AC current abnormal ➢Over load warning
➢Speed reference abnormal
➢Motor cooling fan stop
➢Transformer cooling fan stop
➢Transformer panel
temperature high
Air-cooled
Multi-Level VFD
➢Main power input voltage drop
➢Control power supply voltage drop
➢Connectors disconnected
➢Enclosure door open
➢Input transformer secondary earth fault
➢Inverter cell abnormal
➢Inverter panel cooling fan abnormal
➢Motor cooling fan stop & Timer delay
➢Motor abnormal (Thermistor input or RTD(PT100) input)
➢Upstream incoming panel abnormal
➢Enclosure temperature high
➢Input transformer over heat
16Copyright © Hitachi,Ltd.2010 All rights reserved
Digital I/O
DI-0 Inverter stop command
DI-1 Inverter run command
DI-2 Emergency stop
DI-3 Operation interlock
DI-4 Main circuit breaker (52) closed
DI-5
DI-6
DI-7
DO-0 Pre-charging complete
DO-1 Heavy fault
DO-2 Light fault
DO-3 Inverter running
DO-4 Operation interlock ready
DO-5 Main circuit breaker (52) close command
DO-6 Main circuit breaker (52) open command
DO-7
Air-cooled
Multi-Level VFD
Interface
Analogue I/O
AI-0 Speed (Frequency) reference DC 4-20 mA
AO-0 Motor speed (Estimated) DC 4-20 mA
AO-1 Motor current DC 4-20 mA
AO-2 Spare DC 4-20 mA
AO-3 Spare DC 4-20 mA
DI/O, AI/O cards can be added as option.
Communication protocol
➢Device Net
➢Profibus
➢MODBUS
17Copyright © Hitachi,Ltd.2010 All rights reserved
Efficiency
Efficiency: 97% including input transformer loss
Inverter loss : approx. 1 %
Input transformer loss : approx. 2 %
Air-cooled
Multi-Level VFD
18Copyright © Hitachi,Ltd.2010 All rights reserved
Air-cooled
Multi-Level VFD
Patented Pre-Charge Method
Main power supply
Power supplyfor precharging
IM
resistor
Multi-level Drive
DC.C
Inverter Cell
Pre-charging
circuit
Conventional method
of pre-charge
DC Link
Capacitor
Pre-Charge
Resistance
Thyristor
Patented Pre-Charging circuit
Separated pre-charging circuit
Charged by Low voltage power source
No power loss at running operation
Lower parts count makes higher reliability of the VFD
After completed pre-charging of DC-link capacitors,
the pre-charging circuit is disconnected.
19Copyright © Hitachi,Ltd.2010 All rights reserved
Pre-Charging circuit
A(r.m.s.) Excitation inrush current curve
time (c/s)
100ms
200A
190A(peak) (134A(r.m.s.))
52 breaker closed
Pre-Charge current
Design value
Actual measurement
In case of 6.6kV 3750kVA H-class dry-type transformer
rated current : 328A
The pre-charge function makes excitation
current of input transformer small, too.Design value of inrush current :1256A
Actual inrush current after pre-charge: 134A
(Almost 90% reduction)
Excitation inrush current curve
Air-cooled
Multi-Level VFD
20Copyright © Hitachi,Ltd.2010 All rights reserved
Patented Switching Rotation
Cell U6
Cell U5
Cell U4
Cell U3
Cell U2
Cell U1
+/-6 +/-5 +/-4 …
+/-5 +/-4 +/-3 …
+/-4 +/-3 +/-2 …
+/-3 +/-2 +/-1 …
+/-2 +/-1 +/-6 …
+/-1 +/-6 +/-5 …
+6
+5
+4
+3
+2
+1
0
-1
100% output
80% output
50% outputSw
itch
ing
Lev
el
The lower level cells energize longer and generate heat a lot. On the other hand,
the higher level cells switch frequently and suffer stresses to their gate circuits.
Moreover, some higher level cells do not operate at the low VFD output.
Switching Rotation
Hitachi VFD periodically rotates switching level of each cell so that the stresses of
all cells are leveled. It helps to bring the high reliability.
Hitachi transmission scheme of the switching signal can easily achieve this rotation.
21Copyright © Hitachi,Ltd.2010 All rights reserved
Air-cooled
Multi-Level VFD
Easy Monitoring and Diagnostics
Graphic touch screen
Displays failure status, Reset function available
Operation Screen
Failure Status Display Screen
Cell Inverter Information Screen
Cell Inverter Failure Display Screen
Interlock Display Screen
DI/O Display Screen
Offline Mode Screen
Soft Rev. Display Screen
Controller Malfunction Screen
Item Function
Displays condition and the bar graph of the speed and current
Displays cell inverter and the cell is selectable
Displays failure status of selected cell inverter
Displays incomplete interlock status
Displays input/output condition of contact
Displays offline mode
Displays version information
Displays malfunction occurred in the control system
MalfunctionInterlock Display
I/O StatusOperation Monitoring(Bar Graph)
MalfunctionInterlock Display
I/O StatusOperation Monitoring(Bar Graph)
22Copyright © Hitachi,Ltd.2010 All rights reserved
Graphic touch screen
Operation & monitoring screen Fault message screen Digital I/O screen
Inverter cell selection screen Inverter cell fault message screen
23Copyright © Hitachi,Ltd.2010 All rights reserved
© Hitachi Hi-Rel Power Electronics Pvt. Ltd.. 2014. All rights reserved.
Hitachi Hi-Rel Power Electronics Pvt. Ltd
Hitachi MV VFDs for Cement industry
© Hitachi Hi-Rel Power Electronics Pvt. Ltd.. 2014. All rights reserved.
Wide Range of Product Portfolio
1
Industrial UPS
3Φ Input-1Φ Output System from 10-30 kVA
3Φ Input -3Φ Output System from 10-500 kVA
Battery Charger (Range - 24-360 vDC, up to 1000 A)
Enterprise UPS
Online UPS with 1Φ Input-1Φ Output System from 1-10 kVA
Online UPS with 3Φ Input-1Φ Output System from 10-20 kVA
Online UPS with 3Φ Input-3Φ Output System from 10-300kVA
© Hitachi Hi-Rel Power Electronics Pvt. Ltd.. 2014. All rights reserved.
Wide Range of Product Portfolio
2
Medium Voltage VFD
Multi level - IGBT Drive, Available up to 14.7 MVA (3.3, 6.6 & 11 kV)
Low Voltage VFD
WJ200 – up to 15KW
SJ700 Low Voltage Inverter (415 V Class, 0.75-450 kW)
Engineered Drive System
For Steel & Process Automation and other Industrial Applications
Industrial Automation & Control
PLC-Micro EHV+/EHV+/Micro EH, SCADA, DCS & Automation Panels
© Hitachi Hi-Rel Power Electronics Pvt. Ltd.. 2014. All rights reserved.
Wide Range of Product Portfolio
3
Grid Tied Solar Inverters
© Hitachi Hi-Rel Power Electronics Pvt. Ltd.. 2014. All rights reserved.
Serving Entire Gamut of Industries
4
© Hitachi Hi-Rel Power Electronics Pvt. Ltd.. 2014. All rights reserved.
Sanand Manufacturing Works
5
MODELED ON HITACHI’S OMIKA WORKS, JAPAN
© Hitachi Hi-Rel Power Electronics Pvt. Ltd.. 2014. All rights reserved.
Sanand Manufacturing Works
6
© Hitachi Hi-Rel Power Electronics Pvt. Ltd.. 2014. All rights reserved.
PAN India Presence
7
▪ Sales & Service Network across
Major Cities & Industrial Towns in
India
▪ Dedicated & Decentralized 24X7
After-Sales-Service Locations
▪ Technically Equipped Service
Personnel at various Centres with
Spares
▪ Central Spare Stock in Gandhinagar
© Hitachi Hi-Rel Power Electronics Pvt. Ltd.. 2014. All rights reserved.
Key Customers
8
and many others...
Steel & Metal Power Oil & Gas
© Hitachi Hi-Rel Power Electronics Pvt. Ltd.. 2014. All rights reserved.
Key Customers
9
Cement Others
and many others...
© Hitachi Hi-Rel Power Electronics Pvt. Ltd. 2015. All rights reserved. 10
Reference List
Sl. No.
Client / Project Site End userMVD rating
(KVA) Motor Rating
(kW)Motor
VoltageApplication Qty
1 ACC Limited ACC Ltd, Lakheri, Rajasthan 1460 1200 6.6 Calciner Fan 1
2 ACC Limited ACC Ltd, Lakheri, Rajasthan 1000 650 6.6 Coal Mill Sep Fan 1
3 ACC Limited ACC Ltd, Chanda, Chandrapur, Maharashtra 500 350 3.3 Cement mill -1 Separator fan 2
4 F L Smidth Pvt Ltd Reliance Cement, Kundangunj, UP 4400 6.6 Bag House Fans 2
5 ACC Limited Lakheri, Rajasthan 2200 1350 6.6 VRM Fan 1
6 Ultratech Cements Ltd Ultratech Cement Ltd, Chittorgarh, Rajasthan 4890 3000 11 Pre-heater Fan 1
7 JK Cement Works JK Cement Chittorgarh Works 600 315 3.3 Bag House Fans 1
8 JK Cement Works JK Cement Chittorgarh Works 725 400 3.3 Bag House Fans 1
9 JK Cement Works JK Cement Chittorgarh Works 1100 710 3.3 Bag House Fans 1
10 JK Cement Works JK Cement Mangrol Works. 730 315 6.6 Bag House Fans 1
11 JK Lakshmi Cement Ltd Surat 2200 1250 6.6 Vertical Roller 1
12 JK Lakshmi Cement Ltd Surat 840 600 6.6 CA Fan 1
13 ACC Limited Chanda 800 475 11 BFP 1
14 ACC Limited Chanda 360 250 6.6 BFP 1
15 Ultratech Cements Ltd Sewagram Cement Works, Kutch 2650 1800 6.6 Bag House Fans 1
16 Ultratech Cements Ltd Sewagram Cement Works, Kutch 2650 1800 6.6 Bag House Fans 1
17 Sanghi Cement Sanghi Cement 1450 1050 6.6 Boiler Feed Pump 2
18 Ultratech Cement Ltd Rajashee Cement Works 1090 710 6.6 Fan 1
19 Ultratech Cement Ltd Rajashee Cement Works 2200 1400 6.6 Fan 1
20 Ultratech Cement Ltd Rajashee Cement Works 2650 1800 6.6 Fan 1
© Hitachi Hi-Rel Power Electronics Pvt. Ltd. 2015. All rights reserved. 11
Reference List
Sl. No.
Client / Project Site End userMVD rating
(KVA) Motor Rating
(kW)Motor
VoltageApplication Qty
21 Ultratech Cement Ltd Rajashee Cement Works 2540 1680 6.6 Fan 1
22 Shree Cement Ltd. Shree Cement Raipur Plant 11600 8000 11 Raw Mill 1
23 Shree Cement Ltd. Shree Cement,RAS Site 2900 2400 6.6 Preheater Fan 1
24 Saurashtra Cement Ltd. Saurashtra Cement Ltd., Porbandar 1100 800 3.3 Fan 1
25 Shree Cement Ltd. Shree Cement, Chattisgarh 7060 5400 11 Preheater Fan 1
26 Shree Cement Ltd. Shree Cement, Chattisgarh 5250 1700 11 Kiln Main Drive 1
27 Ultratech Cement Ltd Wanakbori Cement Plant 2900 2350 6.6 Fan 1
28 Ultratech Cement Ltd Hirmi Cement Plant 730 450 6.6 SA Fan 1
29 Ultratech Cement Ltd Awarpur Cement Plant 2650 1850 6.6 Fan 1
30 Ultratech Cement Ltd Ultratech Cement Ltd., Dhar Project 4400 3400 11 Preheater Fan 1
31 Ultratech Cement Ltd Ultratech Cement Ltd., Dhar Project 3625 2800 11 Cement Mill Fan 2
32 Ultratech Cement Ltd Ultratech Cement Ltd., Dhar Project 6550 4700 11 Raw mill Fan 1
33 Loesche India Ltd. Sonapur Raw Project 2200 1500 6.6 Mill Fan 1
34 Shree Cement Ltd. Shree Cement, Rajasthan 3930 3000 6.6 Preheater Fan 2
35 Shree Cement Ltd. Shree Cement Ltd. 3930 3000 6.6 PH Pump 1
36 Shree Cement Ltd. Shree Cement Ltd. 3930 3000 6.6 PH Pump 1
37 Saurashtra Cement Ltd. Saurashtra Cement Ltd., Porbandar 2370 1900 3.3 ID Fan 1
38 Shree Cement Ltd. Karnataka Cement Project. 1410 900 11 Coal mill Fan 1
39 Shree Cement Ltd. Karnataka Cement Project. 1410 950 11 Cooler Fan 1
40 Shree Cement Ltd. Karnataka Cement Project. 1000 710 11 Cooler Fan 4
© Hitachi Hi-Rel Power Electronics Pvt. Ltd. 2015. All rights reserved. 12
Reference List
Sl. No.
Client / Project Site End userMVD rating
(KVA) Motor Rating
(kW)Motor
VoltageApplication Qty
41 Shree Cement Ltd. Karnataka Cement Project. 1000 630 11 Cooler Fan 2
42 Shree Cement Ltd. Karnataka Cement Project. 1410 850 11 Cement Mill Classifier 1
43 Shree Cement Ltd. Bangar Cement Unit . 1410 850 11 Cement Mill Classifier 1
44 Shree Cement Ltd. Karnataka Cement Project. 7060 5400 11 Preheater Fan 1
45 Shree Cement Ltd. Karnataka Cement Project. 2800 1800 11 Raw Mill Bag house Fan 1
46 Shree Cement Ltd. Karnataka Cement Project. 2800 2000 11 Clinker Cooler ESP Fan 1
47 Shree Cement Ltd. Karnataka Cement Project. 2X2800 2X900 11 Kiln Main Drive 1
48 JK Cement Works JK Cement Nimbara works. 1575 1200 3.3 Cooler ID Fan 1
49 ULTRATECH CEMENT LIMITED Birla white 1200 600 6.6 Pre heater Fan 1
50 Humboldt Wedag India Pvt. Ltd. Republic Cement, Bulacan, Phillipines 1145 840 4.16 Raw Mill Bag house Fan 1
51 Humboldt Wedag India Pvt. Ltd. Republic Cement, Bulacan, Phillipines 3140 2600 4.16 Pre-heater Fan 1
52 Humboldt Wedag India pvt. Ltd. Republic Cement, Bulacan, Phillipines 1375 110 4.16 Cement Mill Separator Fan 1
53 Saurashtra Cement Saurashtra Cement 975 750 3.3 Separator Fan 1
54 Shree Cement Ltd. Shree Cement Ltd., RAS 1640 600 6.6 Kiln Main Drive 4
55 JSW Cement JSW Cement, Jajpur 2200 1450 6.6 Roller Press 4
56 Ambuja Cement Ltd. Ambuja Cement Ltd., Bhatapara 1640 1300 6.6 Fan 1
57 Humboldt India Wedag Pvt. Ltd. Iligan Cement, Phillipines 1375 840 4.16 Cement Mill Separator Fan 1
58 Ultratech Cement Ltd. GCW Kovaya 970 560 6.6 Cooler ESP Fan 1
59 Ultratech Cement Ltd. GCW Kovaya 730 450 6.6 Cooler ESP Fan 1
60 Ultratech Cement Ltd. Awarpur Cement works 840 525 6.6 Sepax Fan 1
© Hitachi Hi-Rel Power Electronics Pvt. Ltd. 2015. All rights reserved. 13
Reference List
Sl. No.
Client / Project Site End userMVD rating
(KVA) Motor Rating
(kW)Motor
VoltageApplication Qty
61 JK Cement JK Cement Mangrol 2420 1800 11 Fan 6
62 Birla White Cement Birla White Cement 1200 600 6.6 Pre heater Fan 1
63 Shree Cement Shree Cement 1640 600 6.6 Kiln Main Drive 2
Maximum Rating supplied: 8 MW, 11KV,
for Raw mill application.
Customer: Shree Cements