#Masterdrives CUVC Eng Uusi DC-DC
Transcript of #Masterdrives CUVC Eng Uusi DC-DC
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09.01.2006 DC-AC, 4WD, Long wheel base
RTG-Training, J.Tikka
MasterDrives CUVC Frequency Converters
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SIEMENS AC-Drives
Kalmar RTG-Crane movements are done
by AC - motors.
AC - Drives are control ling motor speed
by changing supply frequency.
More frequency = more speed.
Drives are microprocessor control led
and PLC gives instructions for speed
reference according to operators input.
Speed feedback is fed to dr ive from
pulse-encoder attached to end of motors.
(Closed-loop control)
Motors are connected by shielded supply
cables to minimize any EMC noise.
Drives used are DC-AC type
(Common DC supply via Converter unit)
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SIEMENS DC - AC Drives
Main parts of Frequency Inverter:
Frequency Converter has Three (3) Main
parts.
RECTIFIER:
Rectifies Incoming AC-Power to
DC-Power. (Tyristor-/Diode Rectifier)
DC-LINK:
Smoothens recti fied DC-Power.
(Capacitor Bank)
INVERTER:
Converts DC-Power to AC-Power,
Frequency is adjustable.
CONTROL UNIT:
Controls Transistor switching and
checks that drive works properly.
(CUVC - Card, Control Unit Vector Control )
External
Rectifier DC-Link Inverter
Control Unit
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SIEMENS DC - AC Drives, Hoist Drive
+ - + - + -
Braking Units
2 x 170kW
Braking
Resistors.
3~
AC-MotorHoist
Hoist + Trol ley drive:
One drive is controll ing
one motor.
+ -
AC
toDC
Conv
erterunit
(CommonRectifier)
AC
Power
Source Ho is t
+ -
3~
AC-MotorTrolley
T r o
lle y
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SIEMENS DC - AC Drives, Gantry DS and DOS
+ - + - + -
Braking Units
2 x 170kW
Braking
Resistors.
3~
AC-Motor
Gantry Diesel Side
Gantry DS + DOS drive:
One drive is controll ing
two motors (parallel).
+ -
AC
toDC
Conv
erterunit
(CommonRectifier)
AC
Power
Source
G a ntry D
ie s e lS i d e
+ -
3~
AC-Motor
G a nt ry Di e
s e lO p p o s ite
S
id e
3~
AC-Motor
3~
AC-Motor
Gantry Diesel Opposite Side
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Block diagram of RTG (AC - AC) application (2wheel drive, short)
Gantry DOS, 75 kW
Gantry DS, 75 kW
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SIEMENS DC - AC Drives, 4WD, Acceleration
+ - + -
AC
Power
Source
+ - + -
Braking Units
2 x 170kW
BrakingResistors.
3~
AC-Motor
Ga ntry DOS
+ -
3~AC-Motor
Ga ntry DS
Acceleration:
Power Flows from supply
through AC-drive to Motor.
AC
toD
C
Converterun
it
(Com
monRectifier)
3~
AC-Motor
3~
AC-Motor
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SIEMENS DC - AC Drives, 4WD, Deceleration
+ - + -
AC
Power
Source
AC
toD
C
Converterun
it
(Com
monRectifier)
+ - + -
Braking Units
2 x 170kW
BrakingResistors.
Ga ntry DOS
+ -
Ga ntry DS
Deceleration:
When Drive is braking, motor
generates power.
Power Flows from motor through
Inverter to DC-LINK.
Voltage raises at DC-link, until Brakingunit activates and directs excess
power to Braking Resistor.
DC-LinkVolta
ge>757VDC.
DC-LinkVoltag
eStartsraising
3~
AC-Motor
3~AC-Motor
3~
AC-Motor
3~
AC-Motor
When DC-Link Voltage is
over 757 VDC, Braking Unit
Transistors open and Power
flows to Braking Resistors.
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EMC stands for "Electromagnetic Compatibili ty"
and, in accordance with the EMC Law 2(7),
it defines " the capability of a unit to operate
satisfactorily in an electromagnetic environment,
without itself causing electromagneticdisturbances which would be unacceptable for
other electrical units in this environment" .
In principle, this means that units should not
interfere with each other.
A shielded motor cable with a shield connected
at both sides causes the noise current to flow
back to the frequency converter through the
shield.
Although (almost) no voltage drop arises across
impedance Z E for shielded motor cables, the
voltage drop across impedance Z N can
affect other electrical units.
EMC - limiting the noise
More details: vc332_kompend_kap03_e.pdf
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Incoming Three-phase power
Three-phase power
Drives need power to rotate the motor.
(Comes from Diesel Generator unit )
Power is considered single-phase when it is operated
by one voltage source.
Single-phase power is used for small electrical
demands such as found in the home.
Three-phase power is produced by an alternating
current power supply system equivalent to three
voltage sources.
Three-phase power is a continuous series of three
overlapping AC voltages.
Each voltage wave represents a phase and is offset by
120 electrical degrees.
Three-phase power is used where a large quantity of
electrical power is required, such as commercial and
industrial applications.
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Incoming AC-Voltage supply is rectified to DC-
Voltage by Thyristor rectif ier unit.
DC link has capacitor bank, which smoothens
rectif ied DC Voltage.
DC Voltage is then switched to pulses by IGBTTransistors.
Transistor Inverter stage is giving positive and
negative pulses, that simulate AC voltage.
Each phase needs therefore 2 transistors
(total 6pcs.).
Pulses are PWM modulated (pulse width modulation)
This modulation gives short pulse in beginning of
cycle and longer pulse on middle of cycle, end of
cycle is also short pulse.
Output Voltage is related to area of pulses.
Short (Narrow) pulse -> low Voltage
Long (Wide) pulse -> higher Voltage
Switching frequency between positive and negative
pulses change output frequency.
DC - AC Drive, mode of operation
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These samples show you how pulses
are made with the Transistor inverter.
Notice that Voltage Increases when
pulses are wider!
When running motor on small speeds
= low frequency, pulses are also given
to both positive and negative cycles to
ensure slow Voltage change.
AC - Drive, PWM - Pulse Width Modulation
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Magnetism, Magnetic Flux
Coils in AC-motor are
generating a magnetic field.
Sinusoidal supply changes
magnetic field which is alsocalled as a flux.
Magnetic flux increases when
Voltage level raises.
Magnetic polarity changesaccording Sinusoidal Voltage
polarity.
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A rotating magnetic field must be developed in the stator of
an AC motor in order to produce mechanical rotation of the
rotor.Wire is coiled into loops and placed in slots in the
motor housing.
These loops of wire are referred to as the stator windings.
The fol lowing drawing i llustrates a three- phase stator.
Phase windings (A, B, and C) are placed 120apart.In this example, a second set of three-phase windings is
installed.
The number of poles is determined by how many
times a phase winding appears. In this example, each
phase winding appears two t imes.This is a two-pole stator.
If each phase winding appeared four times it would be a
four-pole stator.
Developing a Rotating Magnetic Field
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Magnetic Field
When AC voltage is applied to the stator,
current flows through the windings.
The magnetic f ield developed in a
phase winding depends on the direction ofcurrent flow through that winding.
The following chart is used here for
explanation only.
It assumes that a positive current flow in the
A1, B1 and C1 windings result in a north pole.
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Magnetic Field
It is easier to visualize a magnetic field i f a
time is picked when no current is flowing
through one phase.
In the illustration, for example, a time hasbeen selected during which phase A has no
current flow, phase B has current flow in a
negative direction and phase C has current
flow in a posit ive direction.
Based on the earlier chart, B1 and C2 are
south poles and B2 and C1 are north poles.
Magnetic l ines of f lux leave the B2 north
pole and enter the nearest south pole, C2.
Magnetic lines of f lux also leave the C1
north pole and enter the nearest south pole,
B1.A magnetic field results indicated by the
arrow.
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If the field is evaluated at 60
intervals from the starting point,
at point 1, it can be seen that
the field will rotate 60.
At point 1 phase C has no
current flow, phase A has
current flow in a positivedirection and phase B has
current flow in a negative
direction.
Following the same logic as
used for the starting point,
windings A1 and B2 are north
poles and windings A2and B1 are south poles.
At the end of six such in tervals
the magnetic field will
have rotated one full revolution
or 360.
Magnetic Field in Rotation
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Magnetic Field:
The amount of flux l ines (Fi) the magnetic field produces is
proport ional to the voltage (E) divided by the frequency (F).
Increasing the supply voltage increases the flux of themagnetic field. Decreasing the frequency increases the flux.
Magnetic Field and Synchronous speed (magnetic field)
Synchronous speed:
The speed of the rotating magnetic f ield is referredto as synchronous speed (NS ). Synchronous
speed is equal to 120 times the frequency (F),
divided by the number of poles (P).
If the applied frequency of the two-pole stator
used in the previous example is 60 hertz,
synchronous speed is 3600 RPM.
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C/L+ and D/L- = Incoming Supply (DC)
ZK = Capacitor bank
WR = IGBT Transistors (DC -> AC)
U2, V2 and W2 = Outgoing Supply (AC)
PSU = Power Supply Unit
IVI = Inverter Value Interface
ABO = Adapter Board
IGD = IGBT Gate Driver
C = Temperature Sensing
CUVC = Control Unit Vector Control
PMU = ParaMeterization Unit
OP1S = Operation Panel
CBP2 = Communication Board Profibus
SIEMENS DC - AC Drive, Block Diagram
W2
V2
U2
ZK
PSU
IVI
OP1S
LAPTOPPMUCBP2
CABO
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SIEMENS DC - AC Drive, Supply fuses
Supply fuses are located on top of
Inverter dr ive.
----------------------------------------------------------
Balancing Resistor is balancing the
charge of the serial connected
capacitors to prevent uneven charge of
capacitors.
(uneven charge can cause damage for
capacitors)
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SIEMENS DC - AC Drive, Capacitor bank
1L+ 1L-
Capacitor bank (Battery) is used for
smoothen the rectified DC-Voltage and
acting as quick resource of sudden
current peaks.
Balancing Resistor is balancing the
charge of the serial connected
capacitors to prevent uneven charge of
capacitors.
(uneven charge can cause damage forcapacitors)
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1
1
1
1
1
X 18X 9
X 258
X 250 X 70
5
16 3
6
13
SIEMENS DC - AC Drive, PSU - Card
X 9 = External 24 V DC supply
X 18 = Power supply from incoming
Phases U1 and V1,
+ Cooling Fan Supply
X 70 = Power supply from DC-link
X 250 = Power supply for IGD-Card
(Only in bigger drives >250kW)
X 258 = Power supply to IVI card
F1, F2 = Fan supply Fuses
POWER SUPPLY UNIT
F1 F2
Power Supply Unit:
- Provides power supply for all cards
- Powered by: - external 24 V DC supply
- Supply from incoming AC power
- Supply from DC link
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6
X 31
1
SIEMENS DC - AC Drive, IVI - Card
X 31 = Temperature sensor ( 5V=20 )
X 33 = Jumper for 3 CTs on HOIST
(Current transformers)
X 41 = Output Current measurement
(From Current transformers)
X 43 = Multiparallel Connection
(No Connection)
X 201 = ABO Connector
X 204 = Power supply for bigger CTs
(No Connection)
X 205 = IGD Control (Flat cable)
X 206 = Shunt connect ion -> PCC Card
X 208 = Power Supply from PSU
**********************************************************************************
IGD Control for Bigger Drives >200kW
U 11,12 = Firing signals for 1stphase IGBT
U 21,22 = Firing signals for 2ndphase IGBT
U 31,32 = Firing signals for 3rdphase IGBT
U 13,23,33= Feedback Signal from IGD card
INVERTER VALUE
INTERFACE
3
X 206
18
X 43
12
X 33
1 7
X 41
1
15
X 208
1 3
X 204
1
X 201
26X 205
1 13
14
1 30
U
11
U
21
U
31
U
12
U
13
U
22
U
23
U
32
U
33
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IGD-Card
Controls
IGBT- Transistor
Firing(PWM Modulation)
PWM Modulated AC ~3 phase out
DC-Link supply
1L+ 1L-
C
E
A(e)
K(c)
G
Sample picture of IGBT Transistor
SIEMENS DC - AC Drive, IGBT Transistors
IGBT = Insulated Gate Bipolar Transistor
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SIEMENS DC-AC Drive, Components
DC
-LINK
IN
(FromCommon
Rectifier)
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SIEMENS AC-Drive, Semiconductors
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f / Hz
60 Hz
IR
U / V
100 %
f / Hz
60 Hz
T P
100 %
TL= T/n
Voltage, Power and Torque
Voltage, Power and Torque of a squirrel Cage motor as a function of the frequency
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OP1S - Operating Panel
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P
Reset
OP1S - Operating Panel, commonly used buttons
Toggle keyis used for selecting menu levels
and switching between parameter number,
parameter index and parameter value. The
current level is displayed by the position of the
cursor on the LCD display(the command comes into effect when the key is released).
Raise keyused for increasing the displayed value
Short press = single-step increase
Long press = rapid increase(If motor potentiometer is active, this is for raising the setpoint).
Lower keyused for decreasing the displayed value
Short press = single-step decrease
Long press = rapid decrease(If motor potentiometer is active, this is for lowering the setpoint).
Reset keyused for leaving menu levels
If fault display active, this is for acknowledging
the fault (resetting).
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OP1S - Operating Panel, Controls
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PMU - Panel, Controls
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PMU - Panel, Commonly used controls
PToggle keyis used for selecting menu levels and
switching between parameter number, parameter
index and parameter value. If fault display active,
this is for acknowledging the fault (resetting).(the command comes into effect when the key is released).
Raise keyused for increasing the displayed value
Short press = single-step increase
Long press = rapid increase(If motor potentiometer is active, this is for raising the setpoint).
Lower keyused for decreasing the displayed valueShort press = single-step decrease
Long press = rapid decrease(If motor potentiometer is active, this is for lowering the setpoint).
ON keyis used for energizing the drive
(enabling motor activation).If there is a fault: For returning to fault displayI
O
OFF keyis used for de-energizing the drive by
means of OFF1, OFF2 or OFF3 (P554 to 560)
depending on parameterization.
OP1S/Laptop connection
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Single Quadrant Driving
In the speed-torque chart there are four quadrants according to direction of rotation and
direction of torque. A singlequadrant drive operates only in quadrants I or III (shaded
area). Quadrant I is forward motoring or driving (CW).
Quadrant III is reverse motoring or driving (CCW). Reverse motoring is achieved by
reversing the direction of the rotating magnetic f ield. Motor torque is developed in the
positive direction to drive the connected load at a desired speed (N).
This is simi lar to driving a car forward on a flat surface from standstill to a desired
speed.
It takes more forward or motoring torque to
accelerate the car from zero to the desired speed.
Once the car has reached the desired speed your footcan be let off the accelerator a little.
When the car comes to an incline a li ttle more gas,
controlled by the accelerator, maintains speed.
T = Torque, N = Speed
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Four-Quadrant / Dynamic Braking
The dynamics of certain loads may require four-quadrant operation.
Torque will always act to cause the rotor to run towards synchronous speed.
If the synchronous speed is suddenly reduced, negative torque is developed in
the motor. The motor acts like a generator by converting mechanical power from the
shaft into electrical power which is returned to the AC drive.
This is similar to driving a car downhill.
The cars engine wil l act as a brake.
Braking occurs in quadrants II and IV.
T = Torque, N = Speed