Harmonics & AFDs Training

South America Sales

May 23, 2012
Francisco Javier García O
RMS Región Andina
FranciscoJGarcia@Eaton.com

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AC Adjustable Frequency Drives

Parts of an AC AFD

Rectifier Filter / DC Bus Inverter

From AC Supply

To AC Motor

• AC Supply: Incoming AC power from the utility power grid (typically 460 Volts, 60 Hz AC)
• Rectifier: Converts (rectifies) utility AC power to DC power
• Filter / DC Bus: The Filter and DC Bus (also referred to as the Intermediate DC Circuit) work
together to smooth the rectified DC power and provide ‘clean’ DC power to the Inverter
• Inverter: Uses DC power from the DC Bus and Filter to create (invert) an output that resembles
sine wave AC power using a Pulse Width Modulation technique.

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 Expected Harmonics
Source Typical Harmonics*
6 Pulse Drive/Rectifier 5, 7, 11, 13, 17, 19…
12 Pulse Drive/Rectifier 11, 13, 23, 25…
18 Pulse Drive/Rectifier 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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 Effect of Harmonics

LINE-SIDE HARMONICS CAN HAVE FAR-REACHING EFFECTS ON THE

POWER SYSTEM:

•Distribution transformers over-heating

•Standby generators over loaded

•Switchgear and relays calibrations affected

•Computers, computer systems affected

•Diagnostic equipment affected

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IEEE 519 – Point of Common Coupling (PCC)

PCC Possible POA’s

(Utility Side) (Customer Side)
Source A Source B MCC-1 MCC-2

Only place that AFD AFD

IEEE 519 applies XFMR
AFD ???

??? AFD

Gen
Set ??? ???

??? = Linear loads for % current distortion

dilution

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Which came first?…..

Voltage Distortion Current Distortion

• In this case…the Egg!
• Current distortion causes Voltage distortion
• Voltage distortion is created by pulling distorted current through an impedance
• Amount of voltage distortion depends on:
• System impedance (NOTE: Generator impedance is typical higher than utility – worst
case)
• Amount of distorted current pulled through the impedance
• If either increases, VTHD will increase

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IEEE 519-1992 Voltage Distortions
Recommended limits
The Institute of Electrical and Electronics Engineers (IEEE)
has set recommended limits on both current and voltage
distortion in IEEE 519-1992.

Voltage distortion limits (@ PCC, ‘Point of Common Coupling’):

Application class THD (voltage)

Special system 3%

General system 5%

Dedicated system 10 %
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 IEEE 519 - Current Distortion Limits
Not THD
Harmonic Current Distortion Limits (Ih and TDD) in % of IL (≤
≤ 69kV)

ISC/IL <11 11≤

≤ h<17 17≤
≤ h<23 23≤
≤ h<35 35≤
≤h TDD
<20 4.0 2.0 1.5 0.6 0.3 5.0
20<50 7.0 3.5 2.5 1.0 0.5 8.0
50<100 10.0 4.5 4.0 1.5 0.7 12.0
100<1000 12.0 5.5 5.0 2.0 1.0 15.0
>1000 15.0 7.0 6.0 2.5 1.4 20.0
• Current distortion limits are dependent on the “stiffness” of the source
(Isc/IL)
• A stiffer source has lower impedance = more distortion allowed
• A softer source (i.e. generator) has higher impedance = less distortion
allowed
• Current distortion limits are typically much more difficult to reach than
Voltage distortion limits

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Harmonics and Generators
Generator Concerns
Generator impedance (16-18%) is generally 3-4 times the equivalent source transformer (5-6%)

Utility Source Generator Source

4.4% Vthd 13% Vthd
Same Load
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 Harmonic Solutions for VFD’s
Oversized
Xs
Generator

G XT

Active
Filter
HCU Model
HVX/SVX
Model 480 V
Phase Shift
Line Blocking 12 / 18 Active Transformers
Isolation
Reactor Transformer Filter Pulse Front
End

M
Tuned M
M + - + - M M
Filter HCX, CPX
CFX Model
Models
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Harmonic Comparison of AC Drives
6-Pulse Converter
35-50% THD
note the level of
distortion and steep
current rise.

12-Pulse Converter
12-18% THD
the waveform appears
more sinusoidal, but
still not very smooth.

6-Pulse w/Harmonic Filter

8-10% THD
Slightly better attenuation
than 12 pulse.

Clean Power (18-Pulse) Converter

< 5% THD
Nearly
indistinguishable from
the source waveform.

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 Harmonic Solutions for VFD’s

Line Reactors (Eaton SVX/HVX), DC Link Chokes (Eaton HMAX)

• K-Rated / Drive Isolation Transformers (MD Models)
• Harmonic Mitigating Transformers/Phase Shifting (HMT Models)
• 12-Pulse Converter (Eaton HCX Model)
• 18-Pulse Converter (Eaton CPX Model)
• 24-Pulse Converter (Eaton SC9000 MV AFD)
• Passive Parallel Tuned Filters (Eaton CFX Model)
• Passive Series Tuned Filters
• Active Filters (Eaton HCU Model, MCCs)
• Active Front End Rectifier

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Line Reactors
• Line Reactor = Inductor
• An inductor slows down the rate of rise of current.

Current Current

• Impedance of an inductor increases as frequency increases

2 2
X = 2πfL
L L Z= R +X
where: f=freq (Hz)
L=inductance (H)
• Reactors have more impedance the higher the harmonic order

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Effect of Drive Line Reactors
Harmonic Reactor Size
Order 0.5% 1.0% 3.0% 5.0% 10.0%
5th 80.0% 60.0% 40.0% 32.0% 23.0%
7th 60.0% 37.0% 16.0% 12.0% 7.5%
11th 18.0% 12.0% 7.3% 5.8% 4.0%
13th 10.0% 7.5% 4.9% 3.9% 2.8%
17th 7.3% 5.2% 3.0% 2.2% 0.4%
19th 6.0% 4.2% 2.2% 0.8% 0.2%
I THD (%) 102.5% 72.2% 44.1% 35.0% 24.7%
IT / I1 143.0% 123.0% 109.0% 106.0% 103.0%

NOTE: ALL Eaton VFD’s come with standard internal ranging from 3-6% line reactors.

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 Input Line Reactor Impedance, HVX/SVX Models

HP (VT) 500V Current Choke uH Capacitors uF % Impedance

10 Fr5 16.0 1000 500 2.2

15 23.0 1000 500 3.1

20 31.0 1000 750 4.2

25 Fr6 38.0 750 1000 3.9

30 46.0 750 1000 4.7

40 61.0 750 1000 6.2

50 Fr7 72.0 450 1650 4.4

60 87.0 450 1650 5.3

75 105.0 450 1650 6.4

100 Fr8 140.0 210 3300 4.0

125 170.0 210 3300 4.9

150 205.0 210 3300 5.9

200 Fr9 261.0 120 6600 4.3

250 300.0 120 6600 4.9

300 Fr10 385.0 72 9900 3.8

350 460.0 72 9900 4.5

400 520.0 60 9900 4.2

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 Drive Line Reactors
Advantages Disadvantages
• Lowest cost • May require larger enclosure
/ separate mounting
• Moderate reduction in
• Harmonic reduction may not
harmonics be sufficient
• Provides increased • Possible voltage drop issues
protection for AFD • Produce heat
• Insensitive to system
changes

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Multi-Pulse VFD’s – 12 Pulse
• Phase shifting isolation transformer provides dual
outputs that go to (2) separate rectifiers. (12 diodes)
• Turns 3-phase power into “6-Phase” power

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Multi-Pulse VFD’s – 12 Pulse
• Phase shifting isolation transformer provides dual
outputs that go to (2) separate rectifiers. (12 diodes)
• Turns 3-phase power into “6-Phase” power
Expanded 12 Pulse Current Waveform

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Multi-Pulse VFD’s – 12 Pulse

Advantages Disadvantages
• Cost varies • Cost varies
• Substantial reduction in • Increased size and weight
harmonics • More complexity
• THD(I) = 9% @ full load • Current distortion is load
11% @ ½ load dependent
• Almost complete cancellation • Doesn’t guarantee
of 5th and 7th harmonics compliance with IEEE 519
• Insensitive to system
changes

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6-Pulse CFX Model
Offering
• 7.5-700 HP @ 480V 50/60hz
• 6 pulse low harmonics drive
• Integral TCI HG7 Harmonic Filter
• Isolation ‘run’ contactor
• 0.1-400HZ frequency range
• 32 Bit Microprocessor
• Low OL/High OL
Points of Difference Customer Value
• Eliminates need for mounting • Only manufacturer with UL Rated
external filter. integral design.
• Reduces footprint due to having 1 • Reduces Harmonic Distortion < 6%-
enclosure vs. 2. 8%THD
• Same enclosed options available. • 208/230vac Available up to 100hp

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 Passive Harmonic Filters (Series / Broadband)

CFX Model ‘PC’ option suffix

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Multi-Pulse VFD’s – 18 Pulse
• Phase shifting isolation transformer provides dual
outputs that go to (3) separate rectifiers. (18 diodes)
• Turns 3-phase power into “9-Phase” power

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Multi-Pulse VFD’s – 18 Pulse
• Phase shifting isolation transformer provides dual
outputs that go to (3) separate rectifiers. (18 diodes)
• Turns 3-phase power into “9-Phase” power
18 pulse input current

18 pulse Utility input voltage

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CPX9000
• Advanced 18-pulse, clean power
technology
• Utilizes SVX9000 drive platform
• Available in standard, modified standard or
custom configurations
• Horsepower range: 25 – 800hp VT, 480V

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CPX9000 Base Dimensions
Enclosure (H x W x D)
HP Eaton (including bypass,
EMI filter, and output dV/dt
filter)

75 90”x30”x21.5”
100 90”x30”x21.5”
150 90”x30”x21.5”
200 90”x48”x25.4”
250 90”x48”x25.4”
Up to 400 90”x60”x26.14”

Up to 600 90”x80”x31.75”
* With EMI filter

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Multi-Pulse VFD’s – 18 Pulse

Advantages Disadvantages
• Guarantees compliance with • Higher Cost
IEEE 519 at the drive terminals
• Must be applied to each VFD
• Up to 4x the reduction of 12
pulse • Attenuation can be affected by
• Excellent for large drives unbalanced voltage
• Substantial reduction in • Increased size and weight vs 6
harmonics or 12-pulse
• THD(I) = 3.5% @ full load
• More complexity
6% @ no load
• Almost complete cancellation of
5th, 7th, 11th, and 13th harmonics
• Insensitive to future system
changes
• Stops the problem at the source
• Efficiency = 95%

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 Medium Voltage Low Harmonic
Drive

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SC9000 Model

Offering
• 300-6,000HP @ 4160 volts
• 300-2,500HP @ 2400 volts
• 24 Pulse low harmonics drive
• Sensorless Vector
• 32 Bit Microprocessor
• Variable & Constant Torque

Points of Difference Customer Value

• Smallest physical size • Smallest footprint in the industry
• Lowest dB level in industry • Lines up with existing and new Ampgard
• Utilizes SVX programming products
• Iso switch, transformer are standard • Single inverter technology assures quick
• Another component of the world repair
leading Ampgard product family • Guarantees IEEE 519 compliance
• 480V control voltage available • Based on “tried-and-true” SMC
internally
technology in the coal mining industry.
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Active Filters

Load(s)
Source XFMR
Typical CT
Placement

HCU
Alternate CT
Placement HCU

• Actively senses harmonics

• Injects equal and opposite currents to cancel harmonic currents
• Multiple units operate in parallel to get additional capacity
• Can also use extra capacity to correct power factor

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Active Filters

Power Schematic

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Active Harmonic Correction Unit

Integration into Motor Control Center

Non-linear
AC Drive Loads
Active Harmonic
Correction Unit

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Active Harmonic Correction Units

Source side Load side

Harmonics Attenuated Harmonics Present

Sensitive
loads
Harmonic producing loads
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Active Filters

Advantages Disadvantages
• Can be sized to guarantee IEEE
519 compliance
• Typically more expensive
• Shunt design cannot be than other methods
overloaded • More competitive where
• Cancels 2nd-50th harmonic redundant VFD’s are used
• Excess capacity can provides 60 • Size
Hz reactive current (PF
correction) • More complex
• Can be incorporated in MCC to
compensate for multiple AFDs
• Fast response to varying loads
• Expandable

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 Harmonics Estimator Analysis Tool

www.eaton.com/drives

Scroll down to bottom right of page under

‘Calculators’ to register/download

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