Transcript Fonction applicatives RSX FR

Altivar 71 Training
Network Braking Units
07/07/20158 Sept 2004 STIE \ Bertrand Guarinos
ATV71_regen-harmonic modules V3 EN
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Summary
ATV71
I.
The Offer
II. How it works ?
III. Sizing principal
IV. Sizing example
V. Appendix
07/07/2015 STIE Bertrand Guarinos
ATV71_regen-harmonic modules V3 EN
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Network Braking Units
I.
ATV71
The Offer
II. How it works ?
III. Sizing principal
IV. Sizing example
V. Appendix
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Introduction
ATV71
 With ATV71 came a new range of option : the Network Braking Unit
 This device allows to regenerate power onto the network when the drive system is
working 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 a good compromise volume/efficiency/cost.
 And the energy saving allows a quick paying off.
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Offer
ATV71
 Customer benefits
•
Small compact housing
•
User friendly first start up, no programming or adjustment necessary
•
Limitation of the harmonic current regen on the main (line chokes)
•
DC-bus coupling of several controllers is possible
•
Up to 4 units can be paralleled (no derating)
•
DC bus short circuit protection (fuses)
•
Overload protection during back feed operation
•
97% efficiency
•
Overvoltage, rotating field sequence and temperature detection
•
IGBT technology
•
Self synchronizing
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When do I need a Network Braking Unit ?
ATV71
 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 <6%)
 Thus the NBU is justified:
•
•
•
•
When there are frequent and quite long cycles of regenerating (braking)
Where the place is a problem
Where heat dissipation is a problem
Where the units can be share by several drives
•
Ex : Hoist movement, high inertia machine
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Offer
ATV71
 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<48%)
•
DC bus protection (fuses + diode)
•
Working temperature :
NBU
Drive
– 5°C…40°C without derating
– 55°C with derating (3%/°C)
•
CE : low voltage directive
•
IP20
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Network Braking Units recommended diagrams
ATV71
ATV71 optional EMC filter
can be used
For power >=45kW an
external 220V supply is
required for fans
Line chokes built in
4%-6% THDI <=40%
Diodes anti current return
built in
DC bus fuses built in
1 NO-NC relay
NBU ready
07/07/2015 STIE Bertrand Guarinos
Ext On/off and reset
ATV71_regen-harmonic modules V3 EN
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Offer
ATV71
Ppeak
400V
380V-415V offer
from 7 to 200kW
continuous braking
power
7,6
13.8
22
33
Ppeak  U m inline .Irmsac . 3
45
70
90
135
160
200
250
345
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Offer
ATV71
Ppeak
440V-480V offer up
to 240kW
continuous braking
power
22
33
45
70
90
110
125
140
160
230
400
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Ex of NBU paying off calculation
ATV71
 Ex for a hoist application
•
Braking power
Braking time per cycle
Number of cycles per hour
Operation hours per day
Working days
Energy-costs
Costs of the power feedback unit
Costs of equivalent braking resistor
•
Energy saving per year
W 
•
= 100kW
= 10s
= 30/ h
= 18h / d
= 350d / y
= 0,1 EUR / kWh
= 6600 eur
= 2800 eur
W  52500 kWh / year
100kW  10s  30 / h  18h / d  350d / y
3600
Energy-costs saving per year:
E W  K
E  52500 kWh / a  0,1eur / kWh
•
Pb
tb
n
h
d
K
RK
CK
E  5250 eur / year
Paying off in days:
A
( RK  CK )
PB  t B  n  BT  K  F
A
(6600eur  2800eur )  3600s
100kW  10s  30 / h  18h / d  0,1eur
A  254 days
The network feedback unit is paid off within 9 months.
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Network Braking Units
I.
ATV71
The Offer
II. How it works ?
III. Sizing principal
IV. Sizing example
V. Appendix
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Network Braking Units internal structure
ATV71
 Internal diagram VW3A7211 (135kW)
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Network Braking Units working
ATV71
 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 10µs.
750-850Vdc
Drive tripping Threshold
Example for a 400V NBU :
620-630Vdc Ir = 120% Imax
NBU tripping Threshold
V
600Vdc Ir = 100% Imax
max peak power
460Vac
III
444Vac
II
IV
400Vac
540Vdc Ir = 0% Imax
I
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Main features
ATV71
 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
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Network Braking Units
I.
ATV71
The Offer
II. How it works ?
III. Sizing principal
IV. Sizing example
V. Appendix
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Sizing of the Network Braking Units
ATV71
 The basics
•
Sizing the Network Braking Units for the technical and economic optimum requires to
know several characteristics of the application.
•
Without this knowledge you choose the NBU in accordance with the continuous and
maximum power rating of the drive.
•
Naturally this will not lead to the best economic solution as most often the NBU will 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
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Sizing of the Network Braking Units
ATV71
 Electrical braking power calculation
•
To size the Network Braking Units you must know :
– the peak braking power Pb to feedback
– the mean braking power Pb to feedback
Ex of a braking power cycle :
Braking power
Pb
Pb 
Pb
t0
Pb1
Pb2
t1
t2
Pb 0 .t 0  Pb1.t1  Pb 2 .t 2
T
T
The power is depending on the cycle, the inertia, the load and the efficiency of the system.
07/07/2015 STIE Bertrand Guarinos
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Sizing of the Network Braking Units
ATV71
 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.
•
The mechanical friction, inverter losses help for braking.
•
These losses are generally represented by the efficiency () of the system.
t  mec .mot .drive
Pbreal  Pbmec t
•
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.
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Sizing of the Network Braking Units
ATV71
 Power flow during regenerating phase
Inputrectifier
Network
Inverter
DC-buscapacitor
L1
L2
L3
Motor
U
V
W
Load
M, w
M
J
3~
Drive
L1
L2
L3
Network Braking Unit
Pr max  Umin .In . 3
Power
regenerated
onto the network
Network
Braking
Units
losses
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
Pb  Pmec .d .mot .mec
Pmec
Braking
power
Motor elec.
power
Motor mec
power
Pdr  Udc .Idc
Pem  Um .Im . 3. cos
Pmm  T .
Inverter
losses
Motor
losses
d 2
 J.
dt
System
mechanical
Power
Mechanical
losses
ATV71_regen-harmonic modules V3 EN
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Sizing of the Network Braking Units
ATV71
 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
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Sizing of the Network Braking Units
ATV71
 Effective regenerating power
•
With a Network Braking Units the power regenerated is depending on the network
voltage.
•
Thus the minimum network voltage must be considered in order to size the unit.
Ex :
– for an application 32kW barking peak power is calculated
– 33kW 400V unit VW3A7204 is chosen
– but the network voltage can decrease to Umin = 340V
– max ac current for VW3A7204 => In = 48A
•
If we take into account the min voltage, the peak regenerating power available is only :
Pr max  Umin .In . 3  Pr max  48.340. 3  28kW
•
It would be better in this case to choose a range above VW3A7205 (45kW 400V)
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ATV71_regen-harmonic modules V3 EN
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Network Braking Units
I.
ATV71
The Offer
II. How it works ?
III. Sizing principal
IV. Sizing example
V. Appendix
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ATV71_regen-harmonic modules V3 EN
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Sizing of the Network Braking Units ex.1
ATV71
 Simplified example for a hoist application
Network = 400V +/-5%
Speed
Braking power reflected on the
motor shaft 160kW
Motor efficiency =0.9
Drive efficiency =0.98
t
up
down
Motor torque
1.8 Tn
Efficiency :
t  0.9  0.98  0.88
0.8 Tn
Peak regenerative power :
Pˆb  1.8  Pn t
3s
30s
3s
40s
3s
Pˆb  1.8 160  0.88  253kW
0.8 Tn
Mean regenerative power :
1.8 Tn
Braking
Power
Pb 
Pb 
T0 = 79s
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T1=40s
Pb 0 .t 0  Pb1.t1  Pb 2 .t 2
.t
T
(0.8  160  40)  (0.5  1.8  160  3)
 0.88  45.5kW
79  40  3
T2=3s
ATV71_regen-harmonic modules V3 EN
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Sizing of the Network Braking Units ex.1
ATV71
 Choice of the braking unit
1- Choose a module witch maximum peak power
is equal or higher the peak braking power
calculated (230kW).
Ppeak power of the module VW3A7212:
Ppeak = Irms*Umain*SQR3
=500*380*SQR3 = 329kW > 253kW
Ppeak
2- Check that the continuous power is
equal or higher than the mean braking
power calculated (45.5kW).
P mean = 200kW >45.5kW
Or check with the duty cycle
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Sizing of the Network Braking Units ex.2
ATV71
 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
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ATV71_regen-harmonic modules V3 EN
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Network Braking Units
I.
ATV71
The Offer
II. How it works ?
III. Sizing principal
IV. Sizing example
V. Appendix
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Example of association of several modules
ATV71
2x Regen
modules
110kW
VW3A7210
ATV71
90kW
ATV71
90kW
ATV71
110kW
Regen
module
26kW
VW3A7205
ATV71
45kW
Up to 4 modules // possible, the
range can be different.
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Calculation of mechanical braking power
ATV71
 Braking power for an horizontal movement (ex trolley)
•
constant deceleration (n->0) and negligible inertia and friction
Braking power
Pb
Pb 
E kin
tb
E kin
1
.m .v 2
2
v   .r .n.i
Pb
Pˆb  2.Pb
tb
Ekin (j) = kinetic energy
Speed
m (kg) = mass of the mobile
n
v (m/s) = linear speed
r (m) = radius of the wheel
n (t/s) = motor speed
i = gearbox ratio
Torque
tb (s) = time to stop
Pb (W) = mean braking power during stopping
Pb (W) = peak braking power during stopping
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Calculation of mechanical braking power
ATV71
 Braking power for an inertia (ex flywheel)
•
constant deceleration (n->0) and negligible friction
Braking power
M
i
Jmot
Pb
Jwh
Pˆb  Tb .2. .n
Pb
Tb  J .
d
2 .n
 Jtm .
dt
tb
J tm  J mot 
tb
Speed
Pˆb
Pb 
2
J wh
i2
Jwh   .v .s
Tb (N.m) = braking torque
Jtm (kg.m2) = total inertia reflected to the motor
Jmot (kg.m2) = inertia of the motor
n
Jwh (kg.m2) = inertia of the wheel
i = gear box ratio
 (kg/m3) = wheel material density
Torque
v (m3) = wheel volume
s (m2) = wheel surface
n (t/s) = motor speed
Tb
tb (s) = time to stop
Pb (W) = mean braking power during stopping
Pb (W) = peak braking power during stopping
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Calculation of mechanical braking power
ATV71
 Braking power for constant speed (ex motor test bench)
•
negligible acc/dec power, inertia and friction
Pˆb  Pb  Tb .2. .n
Braking power
M
G
Pˆb  Pb  m.g.v
Pb
tb
Speed
Tb (N.m) = braking torque
n (t/s) = motor speed
n
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
Torque
Tb
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Calculation of mechanical braking power
ATV71
 Calculation formulas of the braking power for a vertical movement
Braking power
Pb2
Pˆb 2  m.(g  a).v  J .
2
Pˆb1  Pb1  m.g.v
Pb
Pb1
t0
t1
Pb 2 
Pˆb 2
2
Pb 
Pb1.t1  Pb 2 .t 2
T
Pb2
t2
t1
T
T (s) = total cycle time
t0 (s) = stop time + ascent time
(s) = descent time
(s) = stop time in descent
t1
t2
Pb1 (W) = mean braking power during descent
Pb2 (W) = mean braking power to stop in descent
Braking Torque
Pb2 (W) = peak braking power to stop in descent
m (rd/s) = max angular speed
Speed
Jtm (kg.m2) = total inertia reflected to the motor
g (m/s2) = gravity acceleration (9,81)
a (m/s²) = load deceleration
v (m/s) = linear speed
Up
down
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