Presentation on

Latest trends to minimize Harmonics

when using Variable Frequency Drives

Confidential / Property of

Danfoss Drives A/S

8 April 2016
PLPS/INSC-MCS

Contents
VFD- Basics
Harmonics-Basics
Issues related to Harmonics
Harmonic limiting standards
Harmonic solutions and reductions possibility
Advanced Harmonics Solutions
Price/Performance comparisons
Summary
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8 April 2016
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What is a frequency converter ?

Fixed AC Input

Variable AC Output

(3ph,415v,50hz)

( 0-415v,0-x Hz)

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What is a frequency converter ?

What is a frequency converter ?

AC / DC Rectifier

400V,50Hz
Input .

DC Link
Harmonic

Output
StageIGBT

Output
0-400V,0-50Hz

Choke
in
Both
+VE
& -ve

Fixed AC -DC-Filter DC-Variable AC

Motor

Control Speed Reference

V&F

Variable Voltage & Variable Frequency

Confidential / Property of
such that F is changed for change
in motor speed
Danfoss Drives A/S

8 April 2016
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1
0.5
0
-0.5
-10
1
0.5
0
-0.5
-10

Vthd

S max
1

hX I
V1 h
1
h 2

THD

n2

1 PE

1 H
PVSD 2
S nom

2
c

nmax

I RMS I ( n )

I( n )
I( 1)

I n2

I rms

X1
100%
V1

nmax

1
0.5
0
-0.5
-10

1 PE

n 1

1
0.5
0
-0.5
-10

1 PE

1 KPE

hIh

h2

n 1

1
0.5
0
-0.5
-10

1 THD 2

1
100%
I sc

I h h

100%

h 2

1
0.5
0
-0.5
-10

f ( t ) a n sin( n 1 t )

100%

Ih
Hc h
I1
h2

100%

1
THD
I (1)

nmax

2
I ( n ) 100%

n2

I RMS I (1) 1 THD 2

1

PVSD

S nom

(1 THD 2 )

1 THD 2 2 4 1 THD 2 1 H 2c PE 1 PE
2 1 THD 2 1 H 2c PE
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The sinusoidal mains supply could look like

this ...!!!

Voltage/current waveform
(this distorted waveform is what you may see with an oscilloscope!)

3rd Harmonic
150Hz.

Fundamental
Current. 50Hz

Such a non-sinusoidal/distorted waveform is made

Confidential / Property of
up from these
two sinusoidal waveforms
Danfoss Drives A/S

8 April 2016

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with a more complex series of harmonic

currents ..
Harmonic/Fourier
Analysis:

1
0.5

f ( t ) a n sin( n 1 t )

0
-0.5
-1

1
0.5
0
-0.5
-1

The resultant current waveform could look like this.

Confidential / Property of

Harmonic
Frequencies
Danfoss Drives A/S

All periodic signals

can be represented
as a sum of sine
functions with
frequencies equal to
integer numbers of
the fundamental
component
8 April 2016
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Non linear Loads

All frequency inverters are non-

linear loads resulting in

harmonic currents in the mains
supply
UPS systems, Battery charger

etc., also are non linear loads

and result in harmonic current

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8 April 2016
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But.... how do we see harmonics on the mains

supply ?
Generally harmonics appear as distortions
to the sinusoidal mains supply.

But lets take a closer look at what that

means .....

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Harmonic Symptoms/Concerns
Equipment

Failure and malfunctioning

Electronic control malfunctioning, regulator malfunctioning

Overheating and failure of transformers, motors, cables/neutral
Nuisance Operation of fuses, breakers
Insulation deterioration
Capacitor resonance and or failure
Economic Considerations
Over sizing neutrals, transformers, generators
Losses/Inefficiencies/PF Penalties
Inconsistent meter reading
Application of Power Factor Correction Capacitors

Other Issues
Misinterpretation of the IEEE-519 Standard
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Harmonic distortion by nonlinear loads

Non-linear
Non-linearLoad
Load

Current
CurrentDistortion
Distortion

System
Impedance

Contribution
Contributionto
to
system
systemlosses
losses

Voltage
VoltageDistortion
Distortion

Disturbance
Disturbanceto
to
other
otherusers
users

Current distortion is apparatus level performance

Voltage distortion is system level performance
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Which came first?.. ( Chicken or Egg?)

Current distortion causes Voltage distortion
Voltage distortion is created by distorted current through an
impedance
Amount of voltage distortion depends on:
System impedance
Amount of distorted current pulled through the impedance
If either increases, VTHD will increase
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Expected Harmonics in N.L loads

6 Pulse Drive/Rectifier

:5, 7, 11, 13, 17, 19

12 Pulse Drive/Rectifier

: 11, 13, 23, 25

18 Pulse Drive

:17, 19, 35, 37

Switch-Mode Power Supply

:3, 5, 7, 9, 11, 13

Fluorescent Lights

:3, 5, 7, 9, 11, 13

Arcing Devices

:2, 3, 4, 5, 7...

Transformer Energization

:2, 3, 4

Generally, magnitude decreases as harmonic order increases

H = NP+/-1
i.e. 6 Pulse Drive - 5, 7, 11, 13, 17, 19,
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Why do VFDs cause harmonics?

A Basic AC Variable Speed Drive:

Motor
Inverter

Rectifier

The key component in a VFD which affects its

harmonic performance is the Input Rectifier and
associated components ..
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Why do VFDs cause harmonics?

Vab

IDC

Vac

Vbc

IDC

b
c

~
~
~

Non-sinusoidal currents
are drawn from the supply

Ia
Ib
Ic

Pulsating power from the

supply source
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Properties of voltage distortion

Required knowledge to calculate voltage distortion is the harmonic
currents of the non-linear load AND the system short-circuit
impedance.

It is NOT possible to predict the voltage

distortion knowing only the drives
performance.

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IEEE 519 1992

It is currently the only recognized industry standard in North America for setting
harmonic limits (voltage and current)
Designed to limit utility harmonics as well as customer harmonic
the utility grid

contribution to

Standard ONLY applies to the Point of Common Coupling (PCC)

The point where the utility connects to multiple customers
If a utility transformer is provided, the PCC is most likely on the LINE side of the
transformer
IEEE 519 is widely misunderstood and misapplied in the industry

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IEEE 519-1992 & PCC

An important aspect of the IEEE 519-1992 is the definition of the PCC. In
general the PCC is defined as the point of the non-linear load meeting
other loads or the point where the consumer meets the utility.

Medium Voltage Level (e.g.

4160V)

Low Voltage Plant Level (480V)

Equipment Level (480V)

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Standards
IEEE 519-1992
Basically is concerned about potential Disturbance to other users or the
network
i.e.. the voltage distortion mentioned above.

Here we talk about Voltage Distortion.

ANSI/IEEE C57.110
Deals with Transformer and network derating or design. Meaning how much
can I load my transformers, cables, contactors, inductors etc.

Here Current distortion is Key.

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Harmonic Limitings Standards Overview

Name

Type

Countries

IEEE 519-1992

Recommendation

North America

EN 61000-3-2

Standard

Europe

EN 61000-3-12

Future Standard

Europe

G5/4

Recommendation

UK

HK Code of
Practice

recommendation

Hong Kong

EnergieNeed

Recommendation

Netherlands

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Planing level of voltage distortion

USA: IEEE 519 - 1992

THvD

Special/Critic
al application

General
system

Dedicated
system

3%

5%

10 %

Class 1

Class 2

Class 3

5%

8%

10 %

Europe: IEC 61000 - 2 -4

THvD

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Input Current of a basic rectifier

without Harmonic filters
HARMONIC CURRENT ANALYSIS
--------------------------------------------Fund. Current
38.57 A
THD
104.52%
RMS current
55.79 A
5th Harmonic
30.41 A
7th Harmonic
23.64 A
11th Harmonic 10.01 A
13th Harmonic 5.07 A
---------------------------------------------

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Harmonic filter solutions

AC chokes
DC chokes
Passive broadband filter
12 pulse rectifier
Active PWM filter
Active PWM rectifier
12 pulse rectifier
Mixing 1phase and 2 phase rectifiers
18 pulse converter

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Harmonic Reduction Techniques for

AC Drive - Front Ends
Passive
BUS C

///
///

///

BUS A

///

///

AC-inductors

DC-inductors

12/18-pulse etc.

15

BUS B

B6

B6

B6

Phase multiplication

+ Harmonic Broad Band Filters & Harmonic Trap filters.

Active

PWM-rectifier
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///

///

///

B6

Active filter
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Six-pulse Rectifier With Input

AC Inductors
1

~
~

To inverter circuit

AC-side inductors

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Input Current for 6 pulse drive

with AC Input Chokes
HARMONIC
HARMONICCURRENT
CURRENTANALYSIS
ANALYSIS
----------------------------------------------------------------------------------------------Fund. Current
36.84 A
Fund. Current
36.84 A
THD
43.84%
THD
43.84%
RMS
40.22
RMScurrent
current
40.22AA
5th
14.71
5thHarmonic
Harmonic
14.71AA
7th
5.74
7thHarmonic
Harmonic
5.74AA
11th
Harmonic
2.66
11th Harmonic
2.66AA
13th
1.34
13thHarmonic
Harmonic
1.34AA
-----------------------------------------------------------------------------------------------

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8 April 2016
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6 pulse drive with AC Input

Chokes
Advantages.
More robust against mains spikes,
transients and voltage sags.
Maintain power factor over speed and load
range.

Disadvantages.
Bulky, 3 coils to fit.
Power derating due to voltage drop.(8%
reactor 4% voltage drop on output)
Often an additional cost
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Six-pulse Rectifier With Dc-link

Inductor
1

~
~

DC-side inductor(s)

To inverter circuit

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Input Current of 6 pulse drive with DC link

chokes

HARMONIC
HARMONICCURRENT
CURRENTANALYSIS
ANALYSIS
----------------------------------------------------------------------------------------------Fund. Current
36.22 A
Fund. Current
36.22 A
THD
42.51%
THD
42.51%
RMS
39.47
RMScurrent
current
39.47AA
5th
12.91
5thHarmonic
Harmonic
12.91AA
7th
7.03
7thHarmonic
Harmonic
7.03AA
11th
Harmonic
3.06
11th Harmonic
3.06AA
13th
2.10
13thHarmonic
Harmonic
2.10AA
-----------------------------------------------------------------------------------------------

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8 April 2016
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Comparison of harmonic currents from a

Standard/Basic 6 pulse drive and a 6 pulse
drive with DC link chokes

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6 Pulse drive with DC Link

chokes

Advantages.

DC Link capacitor life extended.

No coil, approx. life 40,000 Hours (4 years)
With coil, approx. life 1120,000 Hours (20 years)

No derating due to voltage drop.

Maintain power factor over speed and load range
DC chokes cheaper than AC

Disadvantages:
Can be expensive, difficult to retrofit (VLT6000 fitted
internally as standard).
Extra components needed for transient protection
(VFD includes MOVs for protection as standard)
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8 April 2016
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Comparison of harmonic currents from a

Standard/Basic 6 pulse drive, a 6 pulse drive with
DC link chokes and a 6 pulse drive with DC link
chokes and additional 3% AC input chokes
Com parison of harm onic currents betw een different drive types and harmonic solutions

% of Fundamental current (I1) for each

drive type

120.0%

100.0%

80.0%

60.0%

40.0%

20.0%

0.0%
I1

I5

I7

I11

I13

Harm onic Num ber

Typical 6 pulse drive

Standard VLT6000 (includes DC link chokes)

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VLT6000 plus AC input chokes

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6 pulse drive with DC link chokes

and additional AC input chokes
Advantages
Improvement in harmonic performance
Simple to retrofit
Low cost additional solution

Disadvantages
Voltage drop across AC chokes

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12-pulse Rectifier
12-Pulse Serial

12-Pulse Parallel
N : 3N

Interphase
Reactor

Three-winding
Transformer

N:

ac

N:

ac

dc

3N
2
N
2

dc

Need for extra transformer

Cancels 5th and 7th harmonics
Parallel or serial version
Higher cost (+60% of drive) and larger physical size generally not a
standard off the shelf type Confidential
product
less
reliable
/ Property
of
8 April 2016
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UL

IFC,L

Freq.conv.

IAHF
AHF

Supply

Advanced Harmonic Filter solutions

IM

In between frequency converter and supply

Three wires in / three wires out !
No modification of the Frequency converter !
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8 April 2016
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Input current
with/without AHF (Example)
Only 45KW VFD
THID < 45 %

45kwVFD + AHF 005

THID < 5 %
AHF 005

VLT 6000 series

45kw VFD
+ AHF 010
THID < 10 %
AHF 010

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AHF
Actual input current wave trace from lab test
Wave traces are
displayed out of
phase to make it
easier to see
Input
Actual
of VFD VLT and
Filter on a real
Input of VFD w. AHF Filter
motor

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8 April 2016
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VLT + AHF 010 vs. 12 Pulse

No background THVD distortion or imbalance
30.0

12-pulse ideal

AHF 010 ideal

25.0

THiD [%]

20.0

15.0

10.0

5.0

0.0
0

20

40

60

80

100

120

Load [%]

*Note above graph from tests using programmable power supply

with very short cable between PPS and AHF (i.e. very low impedance).
In real installation, impedance of transformer and supply cables would
improve (reduce) the THID even further.
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Advantages of the AHF

THID < 10% even with up to 2% background THVD
= significantly better than 12-pulse
THID < 5% even with up to 2% background THVD
= better or equal to 18-pulse
3-wires in / 3 wires out
Multiple drives on one filter possible = more cost
effective in some situations, especially if large
number of low power VFDs
Can parallel AHF filter for high power VFDs
Specially designed for Danfoss VFD
Passive filter - no routine maintenance required

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Price-Performance comparisons

Harmonics Reduction
Price

Optimum
Solution!

Active Front
end
18 Pulse
12 Pulse
Harm. trap

Filter
Active

5%
10% Passive
Filter

DC+AC
No Coils
DC Coils

Performance

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100

250

80

200

60

150

40

100

20

50

Basic

ac-coils dc-coils combo

Cost index

THDi [%]

Price-Performance comparisons

THDi max
THDi min
Cost indeks

Quasi 12-pulse passive Active Active

12-pulse
filter Rectifier Filter

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8 April 2016
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Summary on Harmonic Reduction

techniques
while using VFD
DC choke:
Not many drives offer this as standard, however if they are offered,
then it is an ideal solution
AC choke:
When external AC chokes used, 1.5- 5% voltage drop is seen which
is indirect loss to customers
12/18 Pulse:
Loss in efficiency of 1.5% due to transformers ( refer to technical data)
Active filters:
Expensive at present
Passive filters:
Possible best solution as compared to performance
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Danfoss MCT31 harmonic

estimating software

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8 April 2016
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Confidential / Property of

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8 April 2016
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