Reduce harmonics in HVAC&R inverters through C-Less technology Karim Lamrabtine Global Product Manager VSD 14-15 SEPTEMBER 2011, MUNICH
Agenda www.infoplc.net What are Harmonics? Standards Compliance How to reduce Harmonics? Solution comparison Schneider-Electric Solution Conclusion 2
What are Harmonics? Current Voltage Amps, Volts 250Hz 2,5Mz Fluctuations that occur at multiple frequency Harmonic Ranks Harmonic currents are not useful power 3
What are Harmonics? Ideal Wave form Low Frequency Perturbations Real waveform 4
What are Harmonics? A non-sinusoidal signal is equivalent to the sum of its sinusoidal harmonics Key values Total Harmonic Distortion THDI% = I 2 2 I 2 3 I I 1 2 4... I 2 n *100 RMS Current I rms = h h 1 I 2 h 5
Why be concerned about Harmonics? 3 major Negative effects Energy Efficiency Increase I RMS Reduced Power Factor Oversizing Transformer ( I RMS) Cable size, Circuit breaker Elect. Perturbations Standards compliance issues Capacitor bank Resonances Interference with electrical device High Cost Poor Performance 6
What generate Harmonics? Non Linear Load provides I & V distortion onto the main Industrial Equipment Variable Speed Drive Welding machines Rectifier Bridge Domestic Equipment Tv, PC Fluorescent lamps supply Office Equipment Pc, Printers, IT Server Battery charger, UPS I input I input 7
Harmonics : Economical effect Energy Efficiency Operating Cost Investment Cost Reliability Example Transformers life is reduced from 30 to 10 years Production Stoppage Product/Instal Life Cycle 8
150B / Year * Poor Power Quality Costs European Business Up to 10% ** of Company Turnover * European Power Quality Survey ** www.leonardo-energy.org 9
Standards Compliance Statement are current levels of noise generated that may be tolerated by the public network Product level IEC 61000 3-2 I <= 16A per phase, LV Network level IEEE 519 TDD <= 5% al PCC IEC 61000 3-12 16 A < I < 75 A per Phase 10
Standards compliance Machine Energy Efficiency Quality Building Industry IEC 61000 3 Poor EEE 519 THDI % 48% 0% High 11
Variable Speed Drive generates www.infoplc.net Harmonics The current absorbed by a VSD is not sinus it's not a linear load Harmonics Generation Typical AC drive 75kW 6 pulse AC drive without line reactor large current spikes Peak currents 300A Harmonic current distortion Large double humped current THDI = 150% 12
How to reduce Harmonics? www.infoplc.net Possible solution Standard solution Use of Line reactor (AC choke) Use DC choke embedded into VSD VSD THDI % ATV212 C-less Technology No additional product Filter solution Passive filter Active filter Multi pulse solution 12/18/24 pulse solution VSD VSD 13
Best design solution considers Acceptable level of harmonic distortion Installed cost & operating cost Efficiency Cost saving 14
C-Less Technology : www.infoplc.net Reduced Harmonic Technology Rectifier Filtering Inverter Capacitor Charge Harmonics Current Spike Uout distorsion I rms Peak current 15
ATV212 Technology : C-Less www.infoplc.net Reduced Harmonic Technology Drive Life Duration 10% CAPACITORS Others ATV212 Plastic Capacitor 90% Drive s life 16
Harmonic Reduction: solution comparison for 75kW Drive at Nominal speed Drive DC Choke ATV212 C-less Technology THDI 48% Vs THDI 30% 17
Harmonic Reduction: solution comparison for 75kW Drive at Nominal speed Drive DC Choke ATV212 C-less Technology THDI 48% THDI 30% Vs Peak Current I Rms Current spike Humped Waveform : 190A : 161A Peak Current : 180A : 141A I Rms Square Shaped Waveform No humped Waveform 18
Harmonic Reduction: Altivar 212 www.infoplc.net C- less: Reduced Harmonic Technology ATV212 M No additional component Small size & weight Strenghts THDI = 30% I Rms Competitive cost Restrictions Only Variable torque 19
Harmonic Reduction: LC type www.infoplc.net Passive Filter VSD M Strenghts Robustness Good Results with variable torque (No load) Disadvantages Heavy & Large Cost VSD price Additional instal. cost 20
Harmonic Reduction: Dynamic www.infoplc.net Compensation - Active Filter VSD VSD M Strenghts Excellent Perf. < 5% THDI Accept Load variation Disadvantages Heavy & Large Cost VSD price Additional instal. cost 21
Financial Comparative: real case CAPEX Ac Drive vs ATV212 Hotel 8x22 kw Line current Contactors Circuit Breaker Standard Drive 60A Tesys D50 NS80HM A80 ATV212 38A Tesys D32 NS80HM A50 Cables Transformer 16 mm² 10 mm² 800 KVA 630 KVA 22
Financial Comparative: real case OPEX Ac Drive vs ATV212 Hotel 8x22 kw Load Ratio Line losses (200m) Drives losses Standard Drive 1300W 2250W ATV212 830W 1770W Gain 0,6/year Transformer losses 2600W 2470 W Savings: 12MWh x 62* = 750 *French energy cost per / 10kW 23
Altivar 212 The HVAC drive Reduced Harmonic Technology THDI < 30% Embedded C-less 24
Dedicated Drive Solution Altivar 212, is a simple product dedicated for HVAC* applications in Buildings environment OEM Machines Dedicated for Fan & pump Ready for Building Management System Building Protection & Performance * HVAC : Heating, Ventilation, Air Conditioning 25
Some targeted Machines Cooling towers Water-cooled Chillers Boilers Air Handling Units Air-cooled Chillers Rooftop Units 26
Altivar 212 application Air Handling Unit Smoke exhaust Fan (air supply) Air Cooling unit (Condenser, Chillers) Boilers Building Owner needs: Energy saving CAPEX reduction (investment costs) OPEX reduction (operating costs) Application examples: Chillers (compressors, pumps) Roof top (compressors, fans) AHU (fans), Fire or damper management Cooling tower: fan Boilers (pumps and fans) Pumps for circulation of water 27
Key word for Pumps & Fans Drives is: www.infoplc.net 28
ATV212 value proposal for energy efficiency Advanced Energy Saving mode Reduced Harmonic Technology 29
Energy efficiency www.infoplc.net Energy Saving Mode 30% of Energy saving 30
Energy efficiency www.infoplc.net Reduce your Input Current (I rms) 15% to 50% Input Current 6 A 3,8 A 3,2 A 1,5 kw VSD ATV212 RHT Drive DC choke Standard Drive 30% 48% 150% THDI % 31
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Altivar 212 www.infoplc.net Reduced Harmonic Technology Improved efficiency No losses due to line reactor/other external filtering Lower input currents Reduces harmonic distortion 30%THDI only Reduce Energy consumption 10% to 80% compared with other technology Reduces enclosure size requirements No line reactor or other external filtering Reduced capacitance Reduces heat dissipation No line reactor or other external filtering Reduced capacitance Reduces cost of installation Save installation time Wire size, Circuit breaker, transformer minimized Reduces wiring between components 33
ECO² Evaluate your Energy www.infoplc.net Savings potential in HVAC Step 1 : Supply & Motor parameters Step 2 : Industry or Building Step 3 : select IP protection Step 4 : enter your Duty Cycle Step 5 : Adjust Installation cost Result 1 : Electrical & Carbon savings Result 2 : Financial saving Payback period 34
Altivar 212 www.infoplc.net Covers motors from 0.75 kw to 75 kw 240V (3 phases) and 400V (3 phases) Compact format, Heat sink design 14 Sizes to cover IP21 + IP55 0.75 to 2kW 3 to 5kW 7,5 to 11kW 10 to 15 Hp 1 to 3 Hp 5 to 7.5 Hp 15 to 18.5kW 20 to 25 Hp 22 to 45kW 30 to 60 Hp 55 to 75kW 75 to 100 Hp Very Small Foot print up to 22kW 35
Altivar 212 www.infoplc.net Enclosure : Robust, Compact & Certified IP21 / UL type1 IP55/ Nema12 Certified IP21 Certified & integrated IP 21 Protection as a standard. Cabinet cost savings Certified & integrated IP 55 protection class equal to motor IP. 36
Altivar 212 www.infoplc.net More Friendly simplicity & comfort F--- : EXTENDED MENU F100 : Freq. 1 reached F101 : Freq. 2 reached F102 : Freq. 2 bandw. F108 : Logic Funct. 1active F109 : VIA selection Rem Loc/Rem Daisy Chain Universal Graphic Keypad : - Plain Text clear display - Structured Menu : closer of the Schneider Style - 8 Languages (Ch, Sp, It, Fr, Ger, Ru, En, Turkish) - Full compatibility with Drive Schneider Offer (atv32/61/71/312,lex32) - The same part number as ATV71/61 ( vw3a1101) 37
Altivar 212 www.infoplc.net Oriented on Building surveillance Included building fonctions management Fire mode - Motor evacuates smokes with default inhibition Damper control - Motor does not start while damper are not in position Mechanical Protection Function - mechanical chocks limitation with customized ramp - mechanical resonances limitation 38
Altivar 212 www.infoplc.net HVAC features Embedded Solutions Fan Features Fire mode Resonance suppression Damper control Audible noise reduction Flow compensation Pump Features Pressure compensation Pump Load management Mechanical shock suppression Pump Jam management Sleep/wake mode Minimal water supply General HVAC Energy Saving mode Energy monitoring Pressure to Flow conversion Motor rotation protection Multi motor Auto adaptation 39
Altivar 212 www.infoplc.net HVAC features Embedded Solutions Low Harmonics Emissions Cables size saving limit voltage distortion Energy consumption reduction Transformer losses reduction Limit Capacitor Effects EMC Immunity Protection No additional system component (C2/classA) ATV212 Technology Vsd with integrated DC chokes (Up to 100 meters) Comply Building requirement with IEC61000-3-12 Noise reductions High switch Freq 8khz or 12khz (up to 16khz) Motor electric noise Mechanical resonance suppression Audible noise 40
Quickly build your www.infoplc.net automation solution with ready to use Tested, Validated, Documented architectures Make design & installation easier & faster Speeds up commissioning installation & troubleshooting Predetermined equipment lists Tested: in all possible configurations for proper function relative to performance Validated: full functional compatibility of devices Documented: a complete system user guide, predefined CAD panel design and wiring diagrams Visit Our HVAC solution Website 41