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Transcript of ATV71_M10_Network Braking Unit V5 EN_.ppt
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Altivar 71 Training
ATV71_regen-harmonic modules V3 EN 126/10/20148 Sept 2004 STIE \ Bertrand Guarinos
Network B raking Uni ts
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Summary
ATV71
26/10/2014 STIE Bertrand Guarinos ATV71_regen-harmonic modules V3 EN
I The Offer
II How it works ?
III Sizing principal
IV Sizing example
V Appendix
Summary
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Summary
ATV71
26/10/2014 STIE Bertrand Guarinos ATV71_regen-harmonic modules V3 EN
I The Offer
II How it works ?
III Sizing principal
IV Sizing example
V Appendix
Network Braking Units
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Summary
ATV71
26/10/2014 STIE Bertrand Guarinos ATV71_regen-harmonic modules V3 EN
Introduction
With ATV71 came a new range of option: theNetwork Braking Unit
This device allows toregenerate power onto the network when the drive system isworking as a generator.
ATV71 offer is well optimised for duty cycle up to 50% with 5mn braking time
It may replace braking resistors in system witch have quite long generating cycle or
high braking power needs like : hoisting, high inertia machines ..
For such applications, it's agood compromise volume/efficiency/cost.
And the energy saving allows a quick paying off.
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ATV71
26/10/2014 STIE Bertrand Guarinos ATV71_regen-harmonic modules V3 EN
Offer
Customer benefits
Small compact housing
User friendly first start up, no programming or adjustment necessary
Limitation of the harmoniccurrent regen on the main (line chokes)
DC-bus coupling of several controllersis possible
Up to 4 units can be paralleled(no derating)
DC bus short circuit protection(fuses)
Overload protectionduring back feed operation
97% efficiency
Overvoltage, rotating field sequence and temperature detection
IGBT technology
Self synchronizing
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ATV71
26/10/2014 STIE Bertrand Guarinos ATV71_regen-harmonic modules V3 EN
When do I need a Network Braking Unit ?
Advantages of the NBU compare to braking resistors
Energy saving
Volume saving
Efficiency
Quick response
Smooth DC bus voltage regulation
Disadvantages
The cost
Can't regen in case of network cut (no ride through operation)
Can increase a little the network voltage (supply impedance must be
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Summary
ATV71
26/10/2014 STIE Bertrand Guarinos ATV71_regen-harmonic modules V3 EN
Offer
Main specifications
2 power ranges
380V- 415V 7kW to 200kW
440V-480V 18kW to 180kW
Frenquency :40 - 60Hz +/-10%
Effiencency : 97%
Cos = 1
Line inductance(4% to 6% => THDI
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Summary
ATV71
126/10/2014 STIE Bertrand Guarinos ATV71_regen-harmonic modules V3 EN
Offer
7,6
13.8
22
33
45
70
90
135
160
200
250
345
Ppeak
400V380V-415V offer
from 7 to 200kW
continuous braking
power
3..minaclinepeak
IrmsUP
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Summary
ATV71
126/10/2014 STIE Bertrand Guarinos ATV71_regen-harmonic modules V3 EN
Ex of NBU paying off calculation
Ex for a hoist application
Braking power Pb = 100kW
Braking time per cycle tb = 10s
Number of cycles per hour n = 30/ h
Operation hours per day h = 18h / d
Working days d = 350d / y
Energy-costs K = 0,1 EUR / kWh
Costs of the power feedback unit RK = 6600 eur
Costs of equivalent braking resistor CK = 2800 eur
Energy saving per year
Energy-costs saving per year:
Paying off in days:
The network feedback unit is paid off within 9 months.
3600
350183010100 yddhhskWW
///
yearkWhW /52500
KWE
kWheakWhE /ur,/ 1052500 yeareE /ur5250
FKBntP
CRA
TBB
KK
)(
eu rdhhskW
seu reu rA
10183010100
360028006600
,//
)(
days254A
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Summary
ATV71
126/10/2014 STIE Bertrand Guarinos ATV71_regen-harmonic modules V3 EN
I The Offer
II How it works ?
III Sizing principal
IV Sizing example
V Appendix
Network Braking Units
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Summary
ATV71
126/10/2014 STIE Bertrand Guarinos ATV71_regen-harmonic modules V3 EN
Network Braking Units internal structure
Internal diagram VW3A7211 (135kW)
N t k B ki U it ki
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Summary
ATV71
126/10/2014 STIE Bertrand Guarinos ATV71_regen-harmonic modules V3 EN
Network Braking Units working
DC bus management
II The DC-bus voltage increases, when the motor is in regenerative mode. The feedback current increases
straight proportionally with the DC-bus voltage.
IV The difference between the generated and inverted voltage and the mains voltage is the necessary
voltage which drives the current back to the mains. Therefore the mains network operates as energy drain,
where a minimal voltage increase can be seen (depending on the network impedance at this point).
V Between 620 and 630V DC the IGBTs trip due to an overcurrent -> the NBU is locked till reset operation.
The time delay for overcurrent tripping is 10s.
460Vac
444Vac
400Vac
II
I
III
IV
V
620-630Vdc Ir = 120% Imax
NBU tripping Threshold
600Vdc Ir = 100% Imax
max peak power
540Vdc Ir = 0% Imax
750-850Vdc
Drive tripping Threshold
Example for a 400V NBU :
M i f t
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Summary
ATV71
126/10/2014 STIE Bertrand Guarinos ATV71_regen-harmonic modules V3 EN
Main features
Set up
No settings, in factory configuration the NBU is ready to work
However :
Check the supply voltage is corresponding to the NBU name plate
Check the network connection L1,L2,L3 (the phase rotation must be respected)
Check the DC bus connection from the drive (+/-)
Check the fan supply connection (>45kW)
Check the fault relay is connected to external fault input of the drive
At voltage turn on the green led is lighten the NBUis ready to work
In case of fault there are other leds for trouble shooting
1. red: phase failure
2. red: overcurrent
orange: overtemperature
The reset button allows acquit the fault
Internal jumpers allow to set different ways of tripping and autostart in case of fault
N t k B ki U it
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Summary
ATV71
126/10/2014 STIE Bertrand Guarinos ATV71_regen-harmonic modules V3 EN
I The Offer
II How it works ?
III Sizing principal
IV Sizing example
V Appendix
Network Braking Units
Si ing of the Net ork Braking Units
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Summary
ATV71
126/10/2014 STIE Bertrand Guarinos ATV71_regen-harmonic modules V3 EN
Sizing of the Network Braking Units
The basics
Sizingthe Network Braking Units for the technical and economic optimum requires toknow several characteristics of the application.
Without this knowledge you choose the NBUin accordance with the continuous and
maximum power rating of the drive.
Naturally this will not lead to the best economic solutionas most often the NBUwill be
oversized.
The sizing can be done in 3 steps :
- 1. Calculate the electrical braking power to feedback
- 2. Calculate the NBU peak power(function of the minimum network voltage)
- 3. Choose the corresponding NBU power rating
Sizing of the Network Braking Units
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Summary
ATV71
126/10/2014 STIE Bertrand Guarinos ATV71_regen-harmonic modules V3 EN
Sizing of the Network Braking Units
Electrical braking power calculation
To size the Network Braking Units you must know :
thepeak braking power Pb to feedback
the mean braking powerPb to feedback
Ex of a braking power cycle :
The power is depending on the cycle, the inertia, the load and the efficiency of the system.
Braking power
Pb2Pb1
T
t0 t1 t2
Pb
Pb T
tPtPtPP bbb
b
221100...
Sizing of the Network Braking Units
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Summary
ATV71
226/10/2014 STIE Bertrand Guarinos ATV71_regen-harmonic modules V3 EN
Sizing of the Network Braking Units
Real regenerating power
The braking power calculated results of the energy that is fed back from the mechanical
system.
Not the whole energy comes back to the Network Braking Units unit.
Themechanical friction, inverter losses help for braking.
Theselossesare generally represented by theefficiency () of the system.
In an other hand some loads can increase the braking power, as for example the wind
on a crane jib arm.
Anyway, it's good to take a safety margin.
For example, to simplify the calculation, efficiency (if not supposed very bad) can be
considered = 1.
drive m o tm ect ..
tm ecbrealb PP
Sizing of the Network Braking Units
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Summary
ATV71
226/10/2014 STIE Bertrand Guarinos ATV71_regen-harmonic modules V3 EN
Sizing of the Network Braking Units
Power flow during regenerating phase
L1L2L3
UV
W
M
3 ~
Drive
Network Braking Unit
NetworkM, w
J
L1L2L3
Input-rectifier DC-bus-
capacitor
Inverter Motor
Load
Power
regenerated
onto the network
Motor
losses
Mechanical
losses
System
mechanical
Power
Motor elec.
power
Motor mec
power
Inverter
losses
Network
Braking
Units
losses
Braking
power
cos... 3mmem
IUP .TPmm
mecm o tdm ecb PP ... dtd
JPmec
2
.
dcdcdr IUP .
3..minmax nr
IUP
Sizing of the Network Braking Units
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Summary
ATV71
226/10/2014 STIE Bertrand Guarinos ATV71_regen-harmonic modules V3 EN
Sizing of the Network Braking Units
Some efficiency datas*
Drive efficiency
0.37- 1.5kW 0,9-0,94 2.2kW-500kW 0,95-0,97
AC Motor efficiency (standard)
0.37-3kW = 0,75-0.82
4-7.5kW = 0,85
11-55kW =0.9-0.93
75-500kW =0,95
Transmission part efficiency
Gear box = 0.8-0.95
Pignon-Rack = 0.7-0.8
Belt or Chain = 0.95
Endless screw = 0.6-0.8
*Can be used for a first approach calculation
Sizing of the Network Braking Units
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Summary
ATV71
226/10/2014 STIE Bertrand Guarinos ATV71_regen-harmonic modules V3 EN
Sizing of the Network Braking Units
Effective regenerating power
With a Network Braking Units the power regenerated is depending on the network
voltage.
Thus the minimum network voltage must be consideredin order to size the unit.
Ex :
for an application32kW barking peak poweris calculated
33kW 400V unit VW3A7204 is chosen
but the network voltage can decrease to Umin = 340V
max ac currentfor VW3A7204 => In= 48A
If we take into account the min voltage, the peak regenerating power availableis only :
It would be better in this case to choose a range above VW3A7205 (45kW 400V)
kWPIUPrnr 283340483 ....
maxminmax
Network Braking Units
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Summary
ATV71
226/10/2014 STIE Bertrand Guarinos ATV71_regen-harmonic modules V3 EN
I The Offer
II How it works ?
III Sizing principal
IV Sizing example
V Appendix
Network Braking Units
ATV71
Sizing of the Network Braking Units ex.1
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Summary
ATV71
226/10/2014 STIE Bertrand Guarinos ATV71_regen-harmonic modules V3 EN
Sizing of the Network Braking Units ex.1
Simplified example for a hoist application
Motor torque
t
Speed
Network = 400V +/-5%
Braking power reflected on the
motor shaft160kW
Motor efficiency=0.9
Drive efficiency=0.98
Braking
Power
3s 3s 3s30s 40s
T1=40s T2=3sT0 = 79s
1.8 Tn
0.8 Tn
0.8 Tn
1.8 Tn
up
down
kWPb 54588034079
316081504016080..
)..().(
88098090 ... t
tnb PP 81.
t
bbb
bT
tPtPtPP .
...221100
kWPb
25388016081 ..
Peak regenerative power :
Mean regenerative power :
Efficiency :
ATV71
Sizing of the Network Braking Units ex.1
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Summary
ATV71
226/10/2014 STIE Bertrand Guarinos ATV71_regen-harmonic modules V3 EN
Sizing of the Network Braking Units ex.1
Choice of the braking unit
1- Choose a module witch maximumpeak power
is equal or higher the peak braking power
calculated (230kW).
Ppeak power of the module VW3A7212:
Ppeak = Irms*Umain*SQR3 Ppeak
=500*380*SQR3 = 329kW > 253kW
2- Check that the continuous poweris
equal or higher than the mean braking
power calculated (45.5kW).
P mean = 200kW >45.5kW
Or check with the duty cycle
ATV71
Sizing of the Network Braking Units ex.2
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Summary
ATV71
226/10/2014 STIE Bertrand Guarinos ATV71_regen-harmonic modules V3 EN
Sizing of the Network Braking Units ex.2
Exemple of using the catalogue diagram for a cycle
Example 1:
necessary braking power : 33 kW
braking duration : 2 min.
time between two brakes : 5 min.
Evaluation: In this case the point of
intersection of braking time and
intermission time is below
the thermal limited power graph in the
allowed area this operation cycle is
allowed.
Example 2 :
necessary braking power : 45 kW
braking duration : 3 min.
time between two brakes : 3 min.
Evaluation: In this case the point of
intersection of braking time and
intermission time is above
the thermal limited power graph.That means this operation cycle is not
allowed.
Remark: In case of an intermission time
of e.g. 3,5 min. this operation cycle
would be allowed again
ATV71
Network Braking Units
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Summary
ATV71
226/10/2014 STIE Bertrand Guarinos ATV71_regen-harmonic modules V3 EN
I The Offer
II How it works ?
III Sizing principal
IV Sizing example
V Appendix
g
ATV71
Example of association of several modules
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Summary
ATV71
226/10/2014 STIE Bertrand Guarinos ATV71_regen-harmonic modules V3 EN
p
2x Regen
modules
110kW
VW3A7210
ATV71
90kW
ATV71
90kW
ATV71
110kW
ATV71
45kW
Regen
module
26kW
VW3A7205
Up to 4 modules // possible, the
range can be different.
ATV71
Calculation of mechanical braking power
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Summary
ATV71
326/10/2014 STIE Bertrand Guarinos ATV71_regen-harmonic modules V3 EN
g p
Braking power for an horizontal movement (ex trolley)
constant deceleration (n->0) and negligible inertia and friction
Braking power
Pb
tb
Pb
Speed
Torque
bb PP . 2
b
ki n
b
t
EP 2
2
1vmE
kin..
inrv ...
Ekin (j)= kinetic energy
m (kg) = mass of the mobile
v (m/s)= linear speed
r (m)= radius of the wheel
n (t/s)= motor speed
i = gearbox ratio
tb
(s) = time to stop
Pb(W)= mean braking power during stopping
Pb(W)= peak braking power during stopping
n
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ATV71
Calculation of mechanical braking power
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Summary 326/10/2014 STIE Bertrand Guarinos ATV71_regen-harmonic modules V3 EN
Braking power for constant speed (ex motor test bench)
negligible acc/dec power, inertia and friction
Braking power
Pb
tb
Speed
nTPP bbb ...
2
Tb (N.m)= braking torque
n (t/s)= motor speed
v (m/s)= linear speed
g (m/s2)= gravity acceleration
m (kg) = mass of the mobile
Pb(W)= mean braking power during stopping
Pb(W)= peak braking power during stopping
M
n
G
Torque
Tb
vgmPPbb
..
ATV71
Calculation of mechanical braking power
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Summary 326/10/2014 STIE Bertrand Guarinos ATV71_regen-harmonic modules V3 EN
Calculation formulas of the braking power for a vertical movement
T (s)= total cycle time
t0(s) = stop time + ascent time t1
(s)= descent time t2
(s) = stop time in descent
Pb1(W)= mean braking power during descent
Pb2(W)= mean braking power to stop in descent
Pb2(W)= peak braking power to stop in descent
m(rd/s)
=max angular speed
Jtm(kg.m2)= total inertia reflected to the motor
g (m/s2)= gravity acceleration (9,81)
a (m/s)= load deceleration
v (m/s)= linear speed
T
tPtPP bb
b
2211..
Braking power
Pb2Pb1
Pb
T
t0 t1 t2
Pb2
Braking Torque
Speed
vgmPPbb
.. 11
Up
down
1
2
2t
JvagmPb .)..(
2
2
2
b
b
PP