TMdrive-MVG - TMEIC's Medium Voltage AC Drive
TMdrive-MVG - TMEIC's Medium Voltage AC Drive
TMdrive-MVG - TMEIC's Medium Voltage AC Drive
metals
cranes
paper
cement
mining
utilities
Design Feature
Conservative design using 1700-volt IGBTs (Insulated Gate Bipolar Transistor)
Customer Benefit
Highly reliable operation and expected 100,000 hour (12 years) drive MTBF, based on field of experience with the large global installed base of TMdrive-MV technology Considerable energy savings, in particular on flow control applications Capacitors are not required for power factor correction No derating of motor for voltage insulation or heating is required due to motor-friendly waveform
Diode rectifier ensures power factor greater than 95% in the typical speed control range Multiple level drive output waveform to the motor (27 levels for the 6.6 kV inverter, line to line voltage, peak to peak) Multi-pulse converter rectifier and phase shifted transformer: 3.3 kV Class: 18 pulse 10 kV Class: 54 pulse 6.6 kV Class: 36 pulse 11 kV Class: 30 pulse Designed to keep running after utility supplytransient voltage dropouts up to 300 msec.
No harmonic filter required to provide lower harmonic distortion levels than IEEE-519-1992 guidelines
Synchronous transfer to line option with no interruption to motor current (Additional equipment required) Input isolation transformer included in the drive package
Allows control of multiple motors with one drive No motor current or torque transients when the motor transitions to the AC line Better protection of motor Simplified installation Lower cost installation Mitigation of harmonics on the primary side
No output transformer required to match motor voltage, saving cost, mounting space, cabling, and energy Allows easy retrofit of existing motors
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Cement
Accurate torque control is a key in controlling large conveyors. The MVGs flux vector algorithm provides the accuracy and response for this demanding application,. Mining applications include: Raw material conveyor Grinding mills Pumps
Mining
Traditional mechanical methods of controlling flow are inefficient and require considerable maintenance. In the Power Generation Utilities Industry, the MVG provides more reliable, accurate, and energy-efficient control of flow while eliminating the maintenance associated with dampers, vanes, or valves on: Induced and forced draft fans Primary and secondary air fans Boiler feed water pumps Condensate extraction pumps
Utilities/Power Generation
The metal-making part of the steel plant uses large air flows and requires high power levels supplied by the MVG to operate: Water gas fans BOF ID fans Dust collection fans Blast furnace blower fans Utility pumps
Metals
2011 TMEIC Corporation. All Rights Reserved. Page 3 of 16
A A Look Inside
MV Drive Technology for medium voltage operation:
Series connected inverter cell architecture uses 1700 V IGBT inverters for best reliability and high energy efficiency Diode bridge rectifiers yield high power factor operation Multi-winding transformer produces low input power distortion Modular drawable power cell design minimizes the time required for any maintenance activities
Input Transformer
The special input transformer has phaseshifted secondary windings to produce multi-pulse converter operation. This design exceeds the IEEE 5191992 guidelines for input current distortion.
I/O Board
The I/O board supports encoder, 24 V dc I/O, 115 V ac inputs and analog I/O, standard. All I/O are terminated to a two-piece modular terminal block for ease of maintenance, located in right hand cabinet.
Air Cooling
Forced air cooling system with: Intake through cabinet doors Upward flow through inverter cells and transformer Exhaust at top of cabinet
Cell Inverters
Example: six banks of three, series connected inverter cells, each containing: Diode bridge rectifier IGBT PWM inverter DC link capacitor Drawable module for ease of maintenance
Control Functions
A single set of control boards feeds all inverter cells. The primary control board performs several functions: Speed and torque regulation Sequencing I/O mapping Diagnostic data gathering Provision for optional LAN interface
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Input Fuse
Fused three-phase inputs to converter
Control Board
Board passes Pulse Width Modulated control signal to the gate drivers
DC Link Capacitors
Smooth and maintain DC voltage supply to the inverter (on opposite side of module).
2011 TMEIC Corporation. All Rights Reserved.
Page 5 of 16
TMdrive-MVG Architecture
The TMdrive-MVG main circuit consists of an input transformer and single-phase PWM inverter cells. For 3 kV, three inverter cells are series connected to create an output with 7 output voltage levels.
TMdrive-MVG (3 kV class)
3.03.3 kV output
Input transformer, phase shifted secondary windings for low harmonic power system impact
DC-bus capacitor
. . .
Inverter Cell Module
. . .
Single-phase inverter
. . . . .
Diode rectifier
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TMdrive-MVG Specications
3.0/3.3 kV TMdrive-MVG
Approx. Motor Power HP @3.3 kV *2
200 300 400 650 875 1000 1200 1400 1600 1900 2100 2400 4100 4500 2600 3200 5000 6200
Frame
35 I 53 70 105 II 140 167 193 III 228 263 315 350 IV 385 CF 665 CF 727 420 525 V CF 788 CF 998
180 270 360 540 720 860 1000 1180 1360 1630 1810 2000 3450 3770 2180 2720 4090 5180
200 300 400 600 800 950 1100 1300 1500 1800 2000 2200 3800 4150 2400 3000 4500 5700
2100 (83)
2670 (106)
900 (36)
2700 (5940)
2200 (87)
2670 (106)
900 (36)
3400 (7480)
2800 (111)
2850 (113)
1000 (40)
4300 (9460)
2850 (113)
1100 (44)
2895 (114)
1100 (44)
7400 (16280)
11800 (465)
2895 (114)
1100 (44)
Later Later
4600 (182)
2895 (114)
1300 (52)
9400 (20680)
12800 (504)
2895 (114)
1300 (52)
Later Later
Notes: For cabinet clearances, overload ratings, and power calculations, see page 11 *1 1.25 PU overload, 60 sec rating; use Frame Amp rating for most acceptable match with motor *2 Approximate capacity for 3.3 kV-based 6-pole induction motors with typical efficiency (0.94) and power factor (0.87) CF These are two banks; consult factory for dimensions and weights Redundant cooling fans increase height
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TMdrive-MVG Specications
6.0/6.6 kV TMdrive-MVG
Approx. Motor Power HP @6.6 kV *4
400 650 875 1300 1750 2000 2400 2800 3200 3900 4300 4800 7500 8300 9000 5000 6000 6500 10000 11000 12000
Frame
35 I 53 70 105 II 140 167 193 III 228 263 315 350 385 IV CF 595 CF 665 CF 731 420 473 525 V CF 797 CF 898 CF 998
360 540 720 1090 1450 1720 2000 2360 2720 3270 3630 4000 6180 6900 7590 4360 4900 5450 8270 9320 10360
400 600 800 1200 1600 1900 2200 2600 3000 3600 4000 4400 6800 7600 8350 4800 5400 6000 9100 10260 11400
3200 (126)
2670 (106)
900 (36)
3800 (8360)
4000 (158)
2700 (107)
1100 (44)
9100 (20020)
12000 (26400)
15200 (33440)
Notes: *3 1.25 PU overload, 60 sec rating; use Frame Amp rating for most acceptable match with motor *4 Approximate capacity for 6.6 kV-based 6-pole induction motors with typical efficiency (0.94) and power factor (0.87) CF These are two banks; consult factory for dimensions and weights Redundant cooling fans increase height
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10/11 kV TMdrive-MVG
Approx. Motor Power HP @11 kV *6
700 1100 1400 1800 2200 2500 2900 3500 4000 4500 5500 6500 7200 7800 8700 9800 10900
Frame
10 kV Output kVA
11 kV Output kVA
35 I 53 70 87 105 II 122 140 162 191 III 226 263 315 IV 347 386 420 V 473 525
600 900 1200 1500 1800 2100 2400 2800 3300 3900 4500 5400 6000 6680 7200 8100 9000
660 990 1320 1650 2000 2300 2640 3080 3630 4290 5000 6000 6600 7350 8000 9000 10000
5600 (221)
3250 (128)
1400 (56)
8750 (19260)
6800 (268)
3250 (128)
1400 (56)
10850 (23880)
15500 (34110)
18500 (40700)
12800 (504)
3250 (128)
1500 (60)
29350 (64580)
12800 (504)
3250 (128)
1500 (60)
29850 (65680)
Notes: *5 1.25 PU overload, 60 sec rating; use Frame Amp rating for most acceptable match with motor *6 Approximate capacity for 11 kV-based 6-pole induction motors with typical efficiency (0.94) and power factor (0.87) Redundant cooling fans increase height
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TMdrive-MVG Specications
Cabinet Minimum Maintenance Space
Minimum Height of Ceiling for Maintenance
Drive
Frame
Capacity
Ceiling Height
400 kVA 800 kVA 1500 kVA 2200 kVA 3000 kVA 800 kVA 1600 kVA 3000 kVA 4400 kVA 6000 kVA 1320 kVA 2640 kVA 5000 kVA 7350 kVA 10000 kVA
1600 mm (63 in) 1600 mm (63 in) 1700 mm (67 in) 1700 mm (67 in) 1900 mm (75 in) 1600 mm (63 in) 1600 mm (63 in) 1700 mm (67 in) 1700 mm (67 in) 1900 mm (75 in) 1800 mm (71 in) 1800 mm (71 in) 1900 mm (75 in) 2000 mm (79 in) 2000 mm (79 in)
20 mm (0.8 in) 3050 20 mm (0.8 in) 20 mm (0.8 in) 20 mm (0.8 in) 20 mm (0.8 in) 20 mm (0.8 in) 3050 20 mm (0.8 in) 20 mm (0.8 in) 20 mm (0.8 in) 20 mm (0.8 in) 600 mm (24 in) 3500 600 mm (24 in) 600 mm (24 in) 600 mm (24 in) 600 mm (24 in) 3550 3100 3100
Notes 1. kVAInverter = (PowerMtr Shaft) / (Mtr PF x Mtr Eff) IPhase = (kVAInverter) x (1000) / (1.732) x (VMtr Line to Line) Mtr PF 0.87, Mtr Eff = 0.94, ambient temperature is 32F104F (0C40C). Ratings based on a variable torque load (industrial fans and pumps). Altitude above sea level is 03300 ft (01000 m). Dimensions to top of cooling fans are for the nonredundant type fans. 2. An optional bypass circuit can be separately mounted. 3. Redundant cooling fans are available as an option; overall height increases.
4. No rear access is required except for 10/11 kV Class drives. 5. Incoming power cabling and motor cabling are bottom entry; top entry is an option. 6. Air is pulled in through the filters in the cabinet doors and vented out the top. 7. Available options include motor cooling fans and control, cabinet space heater, bypass power/control and dv/dt filter, HV input, sync motor control, smooth transfer to and from utility. 8. For conservative sizing of cooling equipment, heat rejection is 3 kW/100 hp of output power. 9. The panels are fixed to the channel bases and shipped.
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Input Current
Example: 6.6 kV drive at 6,000 kVA and 50 Hz 100% 97.1% 75% 97.2% 50% 97.5%
Power Factor in Italic, Expressed in % * = Interpolated Value 20 Percent of Full Load 40 60 80 100
94.7%
95.5% 96.6%
Additional Specifications
M 311kV output
TMdrive-MVG
Control power for cooling fan 380/400/415/440 V 3-phase 50/60 Hz Control power supply 200 Vac-3 Ph - 50 Hz 220 Vac-3 Ph - 60 Hz Option: 380/400/415/440 V 50/60 Hz Output frequency 4-20 mA Output speed 4-20 mA
Incoming CB close
Power System Input and Harmonic Data Voltage: up to 11 kV, 3-phase, +10%/10% Tolerates power dips up to 25% without tripping, complete power loss ride through of 300 msec 125% Overload (OL) for 60 seconds; other OL ratings available Frequency: 50 Hz or 60 Hz, 5% Power factor (PF): 0.95 lag True PF: greater than 0.95 lag over 40100% speed range Exceeds the IEEE 519-1992 standard for harmonics, without filters Bottom cable entry Converter Type AC-fed multi-pulse diode using phase shifted transformer Transformer Dry type transformer Air cooled type Multi LV windings Inverter Multilevel inverter cells: three in series for 3.3 kV inverter six in series for 6.6 kV inverter nine in series for 10 kV inverter ten in series for 11 kV inverter 072 Hz Up to 120 Hz, option for 3/3.3 and 6/6.6 kV For 10/11 kV, maximum frequency 72 Hz Multilevel output for motor-friendly waveform Applicable Standards IEC61800-4, JIS, JEC, JEM Control Nonvolatile memory for parameters and fault data Vector control with or without speed feedback, or Volts/Hz Designed to keep running after utility supply transient voltage dropouts of 300 ms Synchronous transfer to line option Synchronous motor control (option) Vector Control Accuracy and Response Maximum speed regulator response: 20 rad/sec Speed regulation without speed sensor 0.5% Maximum torque current response: 500 rad/sec Torque accuracy: 3% with temp sensor, 10% without Major Protective Functions Inverter overcurrent, overvoltage Low or loss of system voltage Motor ground fault Motor overload Cooling fan abnormal Over-temperature CPU error
Start/stop sign Emergency stop signal Reference signals +/- 010 V or 420 mA
RUN
EM
Control I/O
Control Area
Analog Inputs Analog Outputs Digital Inputs Digital Outputs Speed Feedback Encoder Input LAN Interface Options
Specifications
(2) 10 V or 420 mA, configurable, differential (4) 10 V, 8-bit, configurable, 10 mA max (2) 24110 V dc or 48120 V ac; (6) 24 V dc, configurable (6) 24 V dc open collector 50 mA High-resolution tach, 10 kHz, 5 or 15 V dc diff. input, A Quad B, with marker Profibus-DP, ISBus, DeviceNet, TOSLINE-S20, or Modbus RTU
Motor Temperature Sensor High-resolution torque motor temperature feedback: 1 K Ohm platinum resistor or 100 Ohm platinum RTD (uses analog input with signal conditioner)
Mechanical Specifications
Operating Environment and Needs Temperature: 0 to +40C Humidity: 85% maximum, noncondensing Altitude: Up to 1000 m (3300 ft) above sea level: Fan: 380/400/440 Vac, 3 phase, 50 Hz or 60 Hz Cooling Air-cooled with fans on top Sound Approx. 76-83 dB(A), at 3.1 ft (1 m) from enclosure Enclosure IP30 except for fan openings (IEC 60529), NEMAI gasketted equivalent Color: Munsell 5Y7/1 (Option: ANSI 61 gray, RAL7032 etc.)
Instrumentation Interface
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Drive/Motor Monitoring
Operator Keypad High Function Display
LCD backlight gives great visibility & long life Bar graphs, icons, menus, and digital values combine to provide concise status information, often eliminating the need for traditional analog meters Easy-tounderstand navigation buttons allow quick access to information without resorting to a PC-based tool Switch to local mode to operate the equipment from the keypad
RJ-45 Ethernet port is used for the local Drive Navigator (toolbox) connection
Instrumentation Interface
Two analog outputs are dedicated to motor current feedback Five analog outputs are mapped to variables for external data logging and analysis
Display Group
Heartbeat
Control State
Fault State
Blank
Blinking
Forward rotation Reverse rotation Drive not ready Drive not running Drive running forward Drive running reverse
The optional multi-language keypad is a touch-panel display with the same functionality as the standard keypad. Chinese version is shown here. The main features are: 5.7 inch (145 mm) LCD color display Choice of languages, touch selection: -English -Japanese -Chinese -Russian -Spanish -French -Portuguese -Italian -Korean
The Ethernet communication with the drive, analog check pins, interlock button, and status LEDs are mounted separately
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Support Functions
Real-Time Drive Block Diagram Control block display Snapshot function Step response test Response wave display
Drive Troubleshooting
This screen displays a drive first fault and shows selected trend displays to assist in determining the cause. The fastest trend displays four variables sampled at a rate of 333 microseconds. The other two slower trends are sampled at 1 millisecond and 100 milliseconds.
1 msec. sampling
Power (pu)
Power (pu)
0.8 o 0.6
0.4
Energy savings
o o
0.2
Electrical ASD
Energy savings
0% 20%
Electrical ASD
80% 100%
20%
40%
60%
80%
100%
40%
60%
RPM/Flow (pu) Example: Pump power savings using electric drive (ASD)
RPM / Flow (pu) Example: Fan power savings using electric drive (ASD)
Below is an example of the energy cost calculation for a pump driven by a motor and electric drive. The calculation for the mechanical system is similar and is described on the next page. Since energy consumption varies with speed and flow, you need the load profile table which shows the number of hours running at the various flows. Refer to the example below.
Energy Cost for Electric Drive Speed Control
Step 9 Energy Cost $0.07/kWh Energy Cost $371,500/yr Step 10 Three-Phase Electric Supply Calculation details Step 1 Select the desired pump output flow, for example 90%, and number of hours/day at this flow, for example 12. Obtain the variable speed pump performance chart and the load pressure-flow curve, which is the flow resistance of the process being fed. Find the pump input power. Convert the input shaft horsepower to shaft kW Obtain the electric motor efficiency Obtain the adjustable speed drive efficiency Obtain the electric power cost Step 7 Electric Adjustable Speed Drive Step 8 Input kW 1,212 Drive Efficiency 96.5% Step 6 Motor Input kW 1,169 Step 4 Motor Shaft kW 1,119
Step 3 Shaft
Output Flow and Pressure Variable speed motor Variable speed pump Overlay the load pressure-flow curve on the pump chart and find the pump input shaft horsepower at the 90% flow (point B). You need the load profile. See example below. Pump input power at N2 rpm = 1,500 hp at point B, 90% flow. Daily Load Profile (example) B 1,500 hp Operation Hours/day Percent Flow 5 100% 12 90% 5 80% 1 70% 1 60%
Step 2
Pump Performance Chart & Load Curve Load Curve Pump Chart (Process) 1,800 rp m Pump hp A 2,000 100
Speed N2
80
Input shaft kW = 1,500 hp x 0.746 = 1,119 kW Motor input power = 1,119 kW/0.957 Efficiency = 1,169 kW Drive input power = 1,169 kW/0.965 Efficiency = 1,212 kW Energy cost = 1,212 kW x 0.07$kWh x 12 hrs/day x 365 days per year = $371,500 per year. (Repeat calculation for other flows in load profile and total).
Example: Induction motor efficiency 95.7% from manufacturer's data sheets (find at each RPM) Example: Drive efficiency 96.5% from manufacturer's data sheets (find at each RPM) Example: Energy cost = $0.07/kWh. Calculate cost for the hours at this flow from load profile; in this example it is 12 hours/day.
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Volts
11,000 10,000
TMdrive-MVG TMdrive-MVG
TM-XL85
7,200 6,600
TMdrive-XL55
3,800 3,300
TMdrive-70
1,250 4 5.4
TMdrive-30
100 134 1,000 1,340 10,000 13,400 20,000 26,800 50,000 67,000 100,000 134,000
kW Hp
Global Office Locations: TMEIC Corporation Ofce: 1325 Electric Road, Suite 200 Roanoke, VA, United States 24018 Mailing: 2060 Cook Drive Salem, VA, United States 24153 Tel.: +1-540-283-2000 Fax: +1-540-283-2001 Web: www.tmeic.com TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION Mita 43 MT Bldg., 13-16 Mita 3 chome, Minato-ku Tokyo, 108-0073 Japan Tel.: +81-3-5444-3828 Fax: +81-3-5444-3820 Web: www.tmeic.co.jp TMEIC Industrial Systems India Private Limited Unit # 03-04, Third Floor, Block 2, Cyber Pearl, HITEC City, Madhapur, Hyderabad, 500081, Andhra Pradesh, India Tel.: +91-40-4434-0000 Fax: +91-40-4434-0034 Web: www.tmeic.in Email: [email protected] Shanghai TMEIC Electric Drive Technology Co. Rm 2901, Shanghaimart, 2299 Yan'An Rd. (W), Changning District, Shangai 200336, P.R. China Tel.: +86 21 62360588 ex 717 Fax: +86 21 64413019 TMEIC Asia Company Limited 152 Beach Road #16-00 Gateway East, Singapore 189721 Tel.: +65 6292 7226 Fax: +65 6292 0817
2011 TMEIC Corporation. All Rights Reserved
TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS (Beijing) CORP. 21/F., Building B, In.do Mansion 48 Zhichunlu A, Haidian District, Beijing 100098, PRC Tel.: +86 10 5873-2277 Fax: +86 10 5873-2208 Email: [email protected] TMEIC Europe Limited Albany House, 71-79 Station Road West Drayton, Middlesex, United Kingdom UB7 7LT Tel.: +44 870 950 7220 Fax: +44 870 950 7221 Email: [email protected] Web: www.tmeic.com Germany Ofce Tel.: +49 699 819 4722 Italy Ofce Tel.: +39 080 5046190
TMdrive is a registered trademark of Toshiba Mitsubishi-Electric Industrial Systems Corporation. All other products mentioned are registered trademarks and/or trademarks of their respective companies. All specifications in this document are subject to change without notice. This brochure is provided free of charge and without obligation to the reader or to TMEIC Corporation, and is for informational purposes only. TMEIC Corporation does not accept, nor imply, the acceptance of any liability with regard to the use of the information provided. TMEIC Corporation provides the information included herein as is and without warranty of any kind, express or implied, including but not limited to any implied statutory warranty of merchantability or fitness for particular purposes. The brochure is not an implied or express contract.
P-1125