Copy Right @ Hitachi Ltd.

HIVECTOLHIVECTOL--HVIHVIMedium VoltageMedium Voltage MultiMulti--LebelLebel IGBT Drives IGBT Drives

Introduction0

Copy Right @ Hitachi Ltd.

　Contents

1．Product Overview1.1　 Introduction1.2　 Evolution of Hitachi’s Drive

1.3　 HIVECTOL-HVI Features

1.4　 Product Lineup

1.5　 Target Application

1.6　 Drive Cabinet Layout

2．Main Circuit Overview2.1　 Circuit Arrangement

2.2　 Operating Principle 　

2.3　 Input and Output Waveform

2.4　 External Pre-charging Circuit

2.5　 Film Capacitor

2.6　 Separation Arrangement of Isolation Transformer

2.7　 By-pass Circuit to Commercial Power Source

2.8　 Separated Wiring

2233 45

789 9

10101111

3．Control Circuit Overview3.1　 Sensor-less Vector Control 　

3.2　 Control Board Construction

3.3　 Graphic Panel

3.4　 Maintenance Tool

3.5　 External Interfaces

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4．Drive Selection4.1　 Selection Flow Chart 　

4.2　 Drive Capacity Selection

4.3　 Energy Savings and CO2 Reduction

5．Data5.1　 Dimensional Outline Drawing

5.2　 Structural Diagram

5.3　 External Interface Terminals

5.4　 Specifications

5.5　 Options

5.6　 Spare parts

5.7　 Efficiency Curve To Rotating Speed

5.8　Specification Form for Estimation

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Copy Right @ Hitachi Ltd.

　 1.1 Introduction

　Product Overview1

●2007

●2001

●1999

●1995

●1986

●1982

●1973

　 1.2 Evolution of Hitachi’s DriveHitachi’s Variable Speed Drive Motor history of 75 years started with the DC motor of Ward Leonard.　With the evolution of power semiconductors, motor drives have evolved from thyristor to GTO to IGBT systems. Based upon our knowledge and experience from these technologies, we have developed HIVECTOL-HVI as a modern industrial motor drive. We use proven and well accepted IGBT devices for multilevel inverter in a configuration to adapt to industry standard voltages such as 2.4kV, 3.3kV, 4.16kV and 6.6kV.

Hitachi was founded as an electrical repair shop for a mining company and had developed its original 5 HP motors in 1910. For over 90 years since then, Hitachi has established a significant install base of wide range of products. By means of latest motor control technology, Hitachi contributes to improving product quality and to achieving energy saving in many industries such as Iron & Steel, Water Treatment, Chemical Processes, Transportation, and Electrical Power.

30MVA IGBT Drives for steel rolling mills delivered

8MVA HIVECTOL-HVI for utility thermal power plants delivered

Medium Voltage Multi -level IGBT Drives, HIVECTOL-HVI, delivered8MVA

20MVA GTO Drives for steel rolling millsdelivered

Medium Voltage AC Drives for steel rolling mills delivered

DC drive controls, HILECTOL, delivered

The world's first Digital Thyrister Leonard Drives delivered

2 　Product Overview

　 1.3 HIVECTOL-HVI FeaturesHigh Performance

High Reliability High Performance

Multilevel conversion method reduces input side harmonics and conforms to the IEEE519-1992 recommended performance without having to use harmonic filter.

High Function High Flexibility

Series connected IGBT cell inverter controls the output waveform distortion and approximates it to a sine waveform. This reduces stress on the motor insulation and enables trouble free application with the existing motors.

High Reliability Low Loss

Reducing the parts count by patented external pre-charging method.

High Reliability Low Cost

Use of long-life film capacitors in the main circuit reduces maintenance costs.

Space Saving

High Performance High Reliability

Patented control method provides smooth starting and operation with high torque loads and impact loads, without use of a speed feedback sensor.

Installation Flexibility

Separate installation of the transformer cabinet and inverter cabinet is possible.

　 1.4 Product LineupUser friendly HIVECTOL-HVI-Power/Voltage Map

13.8

11.0

6.6

4.16

3.32.4

Drive Capacity (kVA)

Outp

ut Vo

ltage (

kV)

Air Cooling Type

500 1,000 5,000 10,000 50,000

13.8

11.0

6.6

4.16

3.32.4

Drive Capacity (kVA)

Outp

ut Vo

ltage (

kV)

Air Cooling Type

500 1,000 5,000 10,000 50,000

Torque Charac

3　 1.4 Target Application

　Product Overview

IndustriesVariable Torque (square law) (Benefit: Energy Saving/CO2 Reduction)

Constant Torque, Constant, Constant Output(Benefit : Flexible and Reliable Production)

Oil & GasFurnace FDF/IDF, Sulfur Recovery BlowerCharge Pump

Large Gas Compressor

ChemicalProcess Fan, Desulfurization Blower,Flux Process Pump, Refrigeration Machine

Polymerization Can, Agitator , Extruder, Cutter, Various type of Compressor

Paper & Pulp Cleaner Pump, Fan Pump, Refiner Paper Machine, Pulper

Ceramic / Earth & RockKiln Air Exhaust Fan, Dust Collection Fan, Cooling Fan, Extractor Fan

Kiln, Crusher , Ball Mill, Vertical Crushing Mill,Grading Machine

Steel / Nonferrous MetalFDF, Furnace Combustion Blower,Dust Exhaust Fan , Descaling Pump

Hoisting Machine, Conveyer

RubberCombustion Air Sending Blower, Feed Pump, Dust Collection Machine

Agitator, Extruder, Conveyer

TextileCombustion Process Blower, Feed Pump,Refrigeration Machines, Dust Collection Machine

Agitator, Extruder, Spinner, Hoisting Machine

Power Generation FDF, IDF, GRF, GMF, BFP Coal Mill, Pulverizing Machine

Food & Beverage Extractor Fan , Air Conditioning Fan Agitator, etc.

Water & Waste Water Water Pump, Waste Water Pump -

Transportation & Logistics Tunnel Ventilation Fan, Wind Tunnel Test Facility -

Machinery Manufacturing Fan Test Facility, Hydraulic PumpTurbine Balance Machine, Test Power Supply Facility

Others Parking Garage Ventilation Fan Others

Common Industry FunctionsBoiler FDF/IDF/GRF/PAF/GMF/BFP,Seawater Pump, Circulation Water Pump

Coal Mill, Petroleum Coke Mill, Biomass Mill

FDF：Forced Draft Fan 　IDF：Induced Draft Fan　GRF：Gas Recirculation FanGMF：Gas Mixture Fan　 PAF：Primary Air Fan　　BFP：Boiler Feed Pump

4

HIVECTOL-HVI is composed of “Isolation Transformer”, “Inverter Section” and “Control Unit”.

　 1.6 Drive Cabinet Layout

　Product Overview

Isolation TransformerIsolation Transformer Inverter SectionInverter Section Control UnitControl Unit

●Components inside the control cabinet, such as relay, electronic boards, control power supply and terminal blocks are mounted on the front side. This facilitates easy component replacement and maintenance.

●Inverter cells are mounted in inverter cabinets. The number of cells depend upon the numberof levels & voltage.

●Transformer secondary phase connections are made from the rear side to each cell.

●Each type of control board, fuse, control powersupply is mounted in front of each inverter cell for easy access and maintenance.

●Depending upon the installation space the transformer can be set right next to the inverter.

●Transformer can also be set separately from the inverter. There is a fan on the top of the transformer cabinet.

●Input power can be fed from either top or the bottom.

Isolation Transformer Inverter Section Control Unit

FanPower Source Connector for Fan

Primary Terminal

Secondary Terminal

Main Transformer

Transformer for Control Source Fuse

Precharge ResistorFan

Output BusCell Inverter

Drive Interface Board

Driver Board

Contactor

Fuse

Relay

Circuit Breaker

Terminal BlockControl Board

5 　Main Circuit Overview

　 2.1 Circuit Arrangement

HIVECTOL HVI inverter uses series connected IGBT inverter cells. Each inverter cell is fed from a separate secondary winding. Each inverter cell has a 6 pulse diode rectifier that supplies DC voltage to two level IGBT inverter section. Series connected cell inverters are switched in multiplexed mode and their output step voltages are added to generate a multi-level output voltage that is closer to a sine-wave form.

Medium Voltage Direct InverterHIVECTOL-HVI Series Circuit Arrangement

Isolation Transformer

Inverter Section

Control Circuit

Medium Voltage Direct InverterHIVECTOL-HVI Series Circuit Arrangement

Isolation Transformer

Inverter Section

Control Circuit

The number of inverter cells in a series connection determine the magnitude of the output voltage.

For example, 4 inverter cells connected in series per phase (total 12 units for three phases) will generate 3kV stepped output and 8 inverter cells connected in series per phase will generate 6kV stepped output.

The isolation transformer has multiple phase shifted secondary windings. Viewed from primary side, there is multi-pulse conversion of AC to DC voltage (The number of shifted phase outputs x 2 conversions per cycle). This offers lesser distortion of the voltage waveform at transformer primary.

6 　Main Circuit Overview

　 2.2 Operating Principle

HIVECTOL-HVI is composed of inverter section which connects multiple transformer and cell inverter, and control circuit section which controls switching.Cell inverter consists of three phase input diode converter and two levels IGBT inverter for one phase output. Cell inverter generates DC voltage from three-phase full wave rectification. For example, for 620V DC per one inverter cell will generate 2480V instantaneous, for 4 cells in series. For 3.3kV output voltage, the inverter will have 4 cells x 3 phases = 12 cell inverters. By star connecting these multistage connected inverter cells, line voltage 3,037 volts can be generated. 3.3 kV output is then achieved by adding 3rd harmonic vector offset to the output voltage vector.Cell inverter can output the waveform which is very close to the sine wave because of multilevel addition of voltages and PWM control by IGBT.

Outp

ut Leve

l of

Each D

rive Level 9

Waveform Phase Voltage

Line Voltage Waveform

7 　Main Circuit Overview

　 2.3 Input and Output Waveform

Along with the development of the power electronics, harmonics generated by the frequency converters are being strictly controlled. For a simple 6 pulse rectifier a harmonic suppression filter may be required to limit magnitude of allowable harmonic currents in the supply line. HIVECTOL-HVI series inverters use phase shifted isolation transformers. Typical 18 pulse or higher rectifier operation eliminates need for any harmonic filters on input side. Inverter section connects single phase IGBT PWM inverter cells to generate a output waveform that is very close to the sine wave. Generally this enables operation with existing motors without need for a output filter. Furthermore, the motor noise during operation is also reduced.

IEEE-519-1992Current Distor tion Guideline

LineLine--side current distortion contentside current distortion content

Harmonics

IEEE-519-1992Current Distor tion Guideline

LineLine--side current distortion contentside current distortion content

Harmonics

Curr

ent dis

tortio

n

Output Current

Output Voltage

Output Current

Output Voltage

8 　Main Circuit Overview

　 2.4 External Pre-Charging Circuit

Pre-charging circuit charges the DC capacitor before the input medium voltage breaker is turned on. This is done in order to prevent the inrush current required by capacitor charging when the medium voltage main power supply turns on.HIVECTOL-HVI uses a separate LV power source for pre-charging. This power supply is switched on for about 20 seconds, during which capacitors in the inverter cells charge. Once capacitor charging is completed, the LV supply is disconnected and the medium voltage breaker for main supply is turned on.

Compared to a pre-charging circuit that uses a thyristorswitch and a resistor in each cell unit, the arrangement of separated pre- charging circuit is simple and easy to maintain. This design leads to high reliability in inverter operation. Separated pre-charging circuit method has been patented by Hitachi Ltd (Patent No.3,535,477).

MediumVoltageBreaker

MediumVoltageMain PS

InductionMotor

Pre-charge PS(200V or 400V)

Cell Unit

MultipleTransformer

InverterInverter

Pre-charging Circuit

DCC

Resistor

MediumVoltageBreaker

MediumVoltageMain PS

InductionMotor

Pre-charge PS(200V or 400V)

Cell Unit

MultipleTransformer

InverterInverter

Pre-charging Circuit

DCC

Resistor

9 　Main Circuit Overview

Capacitors are used to smooth the DC voltage. These capacitors are usually electrolytic type. However expected life-span of electrolytic capacitors is rather short. This may cause frequent capacitor replacement and result in higher maintenance costs.HIVECTOL-HVI inverter uses film capacitors. This type of capacitor has higher durability and longer life-span.Use of film capacitors drastically reduce the amount of maintenance cost for capacitors.

　 2.5 Film Capacitor

Film Capacitor

Tenure of Use

Film Capacitor

Electrolytic Capacitor

Running Running CostCostDeviationDeviation

Runnin

g C

ost

Tenure of Use

Film Capacitor

Electrolytic Capacitor

Running Running CostCostDeviationDeviation

Runnin

g C

ost

10 　Main Circuit Overview

　 2.6 Separation Arrangement of Isolation Transformer

While considering installation of inverter in an air conditioned electrical room, the capacity of the air conditioning unit needs to be considered carefully in order to allow proper air-flow and cooling.The inverter isolation transformer needs to be installed in the electrical room, as it generates heat and causes larger capacity air conditioning units to be installed.The multi-winding isolation transformer can be installed separately from the drive cabinet. The separately installed transformer can also be oil filled.This type of installation saves space in electrical room (pre-fabricated or otherwise) and significantly reduces the required air-conditioning capacity for the electrical room.

Air Conditioner

Air Conditioner

ControlUnit

ControlUnit

InverterSection

InverterSection

IsolationTransformer

IsolationTransformer

Electrical Room

Electrical Room

Air Conditioner

Air Conditioner

ControlUnit

ControlUnit

InverterSection

InverterSection

IsolationTransformer

IsolationTransformer

Electrical Room

Electrical Room

11 　Main Circuit Overview

　 2.7 By-pass Circuit to Commercial Power Source

By-pass circuit is useful primarily for two purposes.・Direct Start of Motor In case of maintenance or failure of inverter, the by-pass circuit can start and run the motor on backup mode.・Soft Starting and Stopping of Motor Inverters are used only during starting or stopping of the motor.　After the motor starts up, the by-pass curcuit is engaged to commercial power source, allowing the motor and the load to gently start and stop.

By-pass Circuit

Induction Motor

Transformer

Multi-level Inverter

By-pass Circuit

Induction Motor

Transformer

Multi-level Inverter

12 　Main Circuit Overview

　 2.8 Separated Wiring

①Avoid electrical noise from inductive loads and radio noise from power cables and ground cables by separating them.

②If the separation of cables is difficult, then use metallic pipe or metallic board as a shield.③Use shielded twisted pair cable for control and field signals.④Set each grounding wire mutually apart.⑤Prepare the specific grounding for the inverter. ⑥Make sure that minimum size for grounding cable is over 38mm2.

During site installation, signal cables, power cables and grounding cables need to be separated.This helps in avoiding any disturbance to field signals and drive control signals from power circuit. Important reminders are as given below:

Transformer

※EB : Medium Voltage Earth TerminalCB : Low Voltage Earth TerminalE1 : Isolation Transformer Power Cross

Preventing Plate Earth Terminal

A TypeGrounding Electrode

A TypeGrounding Electrode(Less than

10Ω) for Low V Circuit

C TypeGrounding Electrode(Less than

10Ω) for Low V Circuit

B TypeGrounding Electrode(Less than

10Ω) for Low V Circuit

Main CircuitOutput Terminal

Main CircuitInputTerminal

Control UnitInverter Section

Earth Terminal

MainPower Supply

Main CircuitOutput Terminal

Main CircuitInput Terminal

Exist Grounding ElectrodeA Type

Main CircuitInput Terminal

Earth Terminal