PM #1 - Embedded Solutions Through Targeted Power Conditioning · Ph: 1-800-377-4384, ) 120 VA...

Embedded Solutions Through Targeted Power Conditioning

Mark Stephens, PEManagerIndustrial Studies Electric Power Research Institute 942 Corridor Park Blvd Knoxville, Tennessee 37932 Phone 865.218.8022 [email protected]

2© 2009 Electric Power Research Institute, Inc. All rights reserved.

Cost of Solutions Versus Knowledge of Sensitivity


Example PQ Solution Levels

Machine or Subsystem Level Power Conditioning

Control LevelPower Conditioning

(1/10th to 1/20th of Machine Level Power Conditioner Cost)

Control LevelEmbedded DC Solution

(Best done by OEM in design phase)


Embedded Solution Strategies

• Use “Selective Power Conditioners” on susceptible loads

• Embed the Solution through proper design, configuration and component selection strategies

• Utilize a Combination of both strategies

DPI and VDC DySC CoilLockCVT and

PowerRide RTD

VacuumPumps

Contactors

DCPower

Supplies

Low VoltageRide Through

Module

Relays

Batteryless Ride-Through Devices(BRTDs)


The Premise:All equipment power users are not ultra-sensitive.

The Plan:To prop up the single-phase “weak links” only.

The Weak Links:Small, single-phase 100Vac-230Vac, typically power supplies, sensors and controls.

The Benefit: Lower Cost than Macro Solutions.

“Selective” Conditioning


Uninterruptible Power Supply (UPS)

Battery Based Battery Based UPSUPS

Are Often Are Often ““OverkillOverkill””

For Control LoadsSmall 500Va to

3kVAUPS Systems are sometimes Used


“Abandoned in Place” UPS Systems

• Throughout our numerous on-site power quality audits we have found many UPS systems “abandoned in place” when their batteries expire

• Without proper maintenance, UPS solutions are not effective


• Off-line (standby) & On-Line models.

• Must consider in-rush current for On-line models.

• Some units have Square Wave Output During Voltage Sag

• Sub-Cycle to several cycle Response. Some critical control components can drop out within 1/4 cycle.

• Sizing for battery time and in-rush current of UPS is manufacturer specific.

• Protects against voltage sags and outages.

UPS Application & FeaturesUPS Application & Features


Square Wave Compatibilitywith PLCs

PLC Model Compatible with 120Vac Input Cards?

Outcome withAPC Smart UPS 420

Outcome withAPC Back UPS Pro 650

Omron (PLC A) No Toggling input could not be resolved

Toggling input could not be resolved

TI 545 (PLC B) No All inputs dropped leading to the logical decision to drop the control relay

All inputs dropped leading to the logical decision to drop the control relay

Quantum (PLC C) No Same as TI 545 Same as TI 545

AB PLC-5 (PLC D) Yes

AB SLC 5/03 (PLC E) Yes No Effect, System OK

No Effect, System OK No Effect, System OK

No Effect, System OK


UPS Coverage vs.Sample Historical Data


Constant Voltage Transformer (CVT)


CVT Application & Features

•On-line Device. In-Rush Current of load(s) MUST be considered in sizing.Output of CVT can collapse when in-rush currentgets close too high ( around 4 x rated size).

• Sub-Cycle Response.

• Should be oversized to at least 2 times nominal of load to increase ride-through.

• Acts as an isolation transformer and protects against voltage sags.


Example CVT Installation


CVT Output

Inpu

t Vol

tage

Out

put V

olta

ge


Sample CVT SizingRecommendations

Specs 250VA 500VA 1kVA 3kVARecommended MaxNominal Load VA/Current @ 120Vac

100 VA / 0.83 A 200 VA / 1.67 A 400 VA / 3.33 A 1200 VA / 10 A

Recommended MaxInrush Load VACurrent @ 120Vac

500 VA / 4.16A 1000 VA / 8.33A 2000 VA / 16.67 A 6000 VA / 50A

Dimensions (inch) 9.88x4.5x7.44 12.69x7.78x6.44 16.75x7.78x6.44 18.69x10.56x9.03Weight (lbs) 27 37 62 142

MIN SIZE = 2.5 X Nominal VAor

1/2 Max Inrush VA*(whichever is larger)

*most critical with contactor loads


Example CVT Application

• The CVT is protecting only the AC control components means that the selected power conditioner will be more affordable than one that could protect the entire machine.

• The ride-though of the AC drives in this example can be enhanced by modifying their programming, thus eliminating the need for a large power conditioner.


CVT Coverage vs.Sample Historical Data


CVT Typical Costs ($USD)

Constant Voltage Transformer (CVT) (Sola/Hevi-Duty. Ph: 1-800-377-4384, www.sola-hevi-duty.com ) 120 VA Catalog No: 63-23-112-4, Cost $245, (8.62” X 3.31 “ X 5.18 “, 15 lbs) 250 VA Catalog No: 63-23-125-4, Cost $400, (9.88” X 4.50” X 7.44”, 27 lbs) 500 VA Catalog No: 63-23-150-8, Cost $650, (12.69” X7.78” X 6.44”, 37 lbs) 750 VA Catalog No: 63-23-175-8. Cost $700, (13.69” X 7.78” X 6.44”, 52 lbs) 1000 VA Catalog No: 63-23-210-8, Cost $850, (16.75” X 7.78” X 6.44”, 62 lbs) 1500 VA Catalog No: 63-23-215-8, Cost $1100 ( 16.44” X 10.56” X 9.03”, 95 lbs) 2000 VA Catalog No: 63-23-220-8, Cost $1200 (17” X 11” X 9”, 109 lbs) 5000 VA Catalog No: 63-23-250-8, Cost $2907 (28” X 11” X 9”, 222 lbs) 7500 VA Catalog No: 63-28-275-8, Cost $3829 (28” X 24” X 9”, 362 lbs) 15,000 VA Catalog No: 63-28-315-8, Cost $6700 (28” X 36” X 9”, 710 lbs)


New Product: UPPI PowerRide RTDBasically a CVT on Steroids!

• Uses two phases of a three-phase supply as input and a single-phase output.

• If one phase in interrupted, constant power out of the RTD....Even if the remaining phase drops by a third.

• Typically No Need to oversize for Inrush


UPPI PowerRide RTD:How It Works

Power Anomaly ResultLoss of Phase A Output remains constantLoss of Phase B Output remains constantLoss of Phase C Output remains constantLoss of Phase A and B -33% sag on remaining phase

Output remains constant

Loss of Phase B and C -33% sag on remaining phase

Output remains constant

Loss of Phase A and C Output goes to 0Loss of A and 33% Sag on C Output remains constantLoss of C and 33% Sag on A Output remains constant37% Sag on A and C Output remains constant


UPPI PowerRide RTD:Example Output


UPPI PowerRide RTD: Suggested List Price

Product Size Qty

Suggested List Price

1 $7792-9 $677

10 + $589

1 $1,1802-9 $1,026

10 + $892

1 $2,0112-9 $1,748

10 + $1,520

1 $2,8812-9 $2,505

10 + $2,178

1 $4,5032-9 $3,916

10 + $3,405

1 $4,8452-9 $4,404

10 + $4,004

1 $7,8932-9 $7,175

10 + $6,523

5kva

7kva

10kva

500va

1kva

2kva

3kva

http://www.uppi-ups.com


Power Ride RTD Coverage vs.Sample Historical Data

(Red Box is coverage for Single-Phase Sags & Phaseto-Phase Sags (A-B, B-C) Blue Box for Phase-to-Phase Sags (A-C)


The Dip Proofing Inverter

• No batteries; therefore, no replacement and maintenance costs or hazardous waste.

• Fast (<700µS) transfer, off-line system develops little heat & fails to safety.

• Able to withstand high inrush currents; no need to oversize as with UPS’s & CVT’s.

• Lightweight, small & easy to retrofit; no step-up transformers or batteries.

• Accurate application control; adjustable ride through time & variable transfer level.

• Primarily designed for inductive and low power factor loads.


Typical Connections


Sample DPI Specifications (120V Models)

Specs 250VA 500VA 1kVA 3hkVANominal LoadCurrent

2A 4A 8A 25A

Useable StoredEnergy

45J 90J 180J 540J

Ride-ThroughTimer Range

0.01 to 2.56 Seconds

Transfer LevelRange

50% to 80%50% to 90% Recommended (Special Order)

Dimensions (inch) 7.68x12.25x6.4 11.4x12.25x6.4 15.75x12.25x6.4 21x12.25x6.4Weight (lbs) 11 17 22 31


DPI Output

Inpu

t Vol

tage

Out

put V

olta

ge

•1-3 second ride-through based on real power required and sizing.

Square Wave not compatible with some PLC AC Input Cards.


DPI Used in Chiller Control Circuit

DPI


DPI Coverage vs.Sample Historical Data


DPI Typical Costs


Voltage Dip Compensator (Vdc)

• No batteries; no maintenance. • Fast compensation. • Able to withstand high inrush

currents. • Small footprint, easy to retrofit. • Support exceeds SEMI F47

standard requirements. • Handles inductive and low power

factor loads.• 120Vac and 208Vac Models• Currently under evaluation by EPRI

PEAC


VDC Output

Product by Dip Proofing Technologies

www.dipproof.comwww.measurlogic.com

AC Output is a Sine Waveinstead of a Square Wave


VDC Coverage4T Model – Down to 50%

6T Model – Down to 37%


VDC Coverage (4T Model) vs.Sample Historical Data


Typical VDC Pricing


Dynamic Sag Corrector

• Draws power from remaining sagged voltage down to 50% of nominal voltage, and injects a series voltage to regulate a sinusoidal output voltage

• Below 50%, draws power from internal storage capacitors

• Mega and Pro DySC have on board event logging.

MiniDySC

Single-Phase Protection

1-50 Amps

ProDySC

Three-Phase Protection

25-200Amps

MegaDySC

Three-Phase Protection

400-3200Amps


Example DySC Output

Input Voltage (Van)

Missing Volts

DySC Output Voltage

-500-400-300-200-100

0100200300400500

0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5

t ( s)

-500

-300

-100

100

300

500

0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5

t ( s)

-600

-400

-200

0

200

400

600

0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5

t ( s)


Voltage Sag Correction & Ride-Through Times

• Ride-Through Times: (Based on 100% load, 0.7PF at 60Hz line frequency)

• Standard Runtime: 2 seconds for sags from 87% to 50% of nominal voltage every 60 seconds – Up to 5 seconds coverage on

Extended Run-Time Models

• 3 cycles for Standard Outage units from 50%-100% (zero voltage remaining)

• 12 cycles for Extended Outage units from 50%-100% (zero voltage remaining)


Extended Run-Time Models Are Available


MiniDySC Coverage vs.Sample Historical Data

Orange – Extended Ride-Through Full LoadRed – Standard Ride-Through Full Load


MiniDySC Typical Cost

www.softswitch.com

1.5kVA 120Vac Single Phase MiniDySC DS10012A120V2SH1000A $2000.00

3kVA 120Vac Single Phase MiniDySC DS10025A120V2SH1000A $2820.00

6-7kVa 120Vac Single Phase MiniDySC DS10050A120V2SH1000A $4570.00


New Product - WaveSync – Ride Through Controller

• The WaveSync was developed by Bay Controls (the parent company of Phase Solutions) R&D based on research conducted by Advanced Energy. It was developed as a solutions to the problem of motor ride through during momentary power interruptions.

• www.phasesolutions.com


WaveSync Operation

• The WaveSync performs four primary operations to accomplish ride through.

1. Monitor supply power to detect the beginning of a momentary outage event.

2. Open the motor contactor upon event detection.3. Keep any motor control center associated with the

protected motor “alive” during the event.4. Once the event has ended, re-close the motor contactor at

the appropriate time, preventing torque and current spikes.5. Can be setup to treat voltage sag like and outage and

perform same function


During the Momentary Interruption

• The WaveSync is working during a momentary interruption. – Monitoring the three phase supply power and,– Monitoring the three phase motor back EMF,– Supplying power and a run signal to any motor control

center– Reconnection of power when supply and motor back EMF

are in phase, or upon decay of back EMF at or below a predetermined level.

– REQUIRES POWER CONDITIONER TO KEEP WAVESYNC POWERED DURING MOMENTARY INTERRUPTION (such as DPI).


During Voltage Sags

• The WaveSync is configured to handle voltage sags below a preset value as a momentary outage.

• The device will hold in the contactor during sags at or above the outage setting.

• During long duration sags, motors are protected utilizing existing over current protection - the WaveSync does not interfere with motor protection systems


Reconnecting Power in Phase

1000

200

400

600

800

0

200

400

600

800

100055 60 65 70 75 80

Motor Contactor Energized

Motor Energized Safely (In-Phase)

Supply Voltage Restored

Cycles

Vol

ts


• Designed to “Prop Up” individual relays and contactors. Available at 24, 120, 230 and 480Vac.

• Holds in down to 10 to 20% of %Vnominal.• Ideal for Motor Control Center Applications.• Size Based on Voltage and Coil Resistance.• Cost: less than $100 per unit

Coil Hold-in Devices

CoilLock Low VoltageRide Through

Module


Coil Hold-In Device Ride-Through Curve


Coil Hold in Device Application


Sizing Coil Hold In Devices

Name ManufacturerInformation

PhaseRef

CoilResistance(ohms)

KnowTripModel

ContactorK1

Gould Cat2250H15

φΑ 10.5 120

ContactorK2

Gould Cat2250H15

φΑ 10.5 120

K15 Gould 2210DP φΑ 326 120AK16 Cutler Hammer

D5PR3A(ice cube)

φΒ >800 120B

K17 Gould 2210DP φΒ 326 120AK18 Cutler Hammer

D5PR3A(ice cube)

φC >800 120B

K20 Cutler HammerD5PR3A(ice cube)

φΒ >800 120B

K22 Gould 2210DP φΑ 326 120AK23 Gould 2210DP φΑ 326 120A

SIZED BASED ON

1. AC Coil Voltage2. Resistance of Coil

Model 120: 8-200 ohmsModel 120A: 201-800 ohmsModel 120B: 801+ ohms

Actual Semi Tool Relays with KnowTrips Recommended.

www.scrcontrols.comwww.squared-semi.com

www.pqsi.com


Overview of Power Quality CoverageType of Event

DPI VDC CVT RTD MiniDySC UPS Coil Hold-in Devices

Spikes and Surges

No No Solves Solves Solves Solves Yes (Coil Lock)No (Knowtrip)

Sags to 80% of Nominal Voltage

Solves Solves Solves Solves for a single phase events and most two phase events

Solves Solves Solves

Sag to50-80% of Nominal Voltage

Solves Solves Solves Depending on Sizing of Device

Solves for a single phase events and most two phase events


Sags to 25-50% of Nominal Voltage

Solves No Solves Depending on Sizing of Device

Solves for a single phase events and most two phase events


Outage Solves -time depends on load and unit size

No No Solves for a single phase events

Solves -time depends on load and unit size

Solves No


Power Conditioner Web Sites

Batteryless Ride-Through Devices (BRTD) Standby Inverter Technology

Dip-Proofing Technologies www.dipproof.com

www.measurlogic.com

Active Ferro Technology

Uninterruptible Power Products (UPPI)

www.uppi-ups.com

DC bus hold-in Technology

Bonitron www.bonitron.com

DC bus hold-in Technology

Maxwell Technologies www.maxwell.com

Coil and Relay hold-in products

Power Quality Solutions www.pqsi.com

Coil and Relay hold-in products

SCR Controls www.scrcontrols.com

Voltage Compensation Technology

Soft Switching Technology www.softswitch.com


Power Conditioner Web Sites (continued)

Constant Voltage Transformers (CVT) BEST Power www.bestpower.com

Sola www.sola-hevi-duty.com

Shape Electronics www.shapelectronics.com

Controlled Power www.controlledpwr.com/

Power Quality Solutions www.pqsi.com

UPPI (PowerRide-RTD) www.uppi-ups.com

Uninterruptible Power Supplies (UPS)Standby, Line-interactive

APC www.apcc.com

Standby,Line-interactive,Ferroresonant

BEST Power www.bestpower.com

Standby, On-line Exide www.exide.com

Standby, On-line Liebert www.liebert.com

On-line Clary www.clary.com

Standby Tripplite www.tripplite.com

On-line MGE UPS Systems www.mgeups.com

Rotary Piller www.piller.com/

PM #1 - Embedded Solutions Through Targeted Power Conditioning · Ph: 1-800-377-4384, ) 120 VA...

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Transcript of PM #1 - Embedded Solutions Through Targeted Power Conditioning · Ph: 1-800-377-4384, ) 120 VA...