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Active Front End
STI - Power DrivesSeptember 2009
Schneider Electric 2 - Engineered Drives - Martin Gradner – March 2009
Active Front End (AFE)
Feedback energy
Reduce energy costs
Increase power quality
Harmonic mitigation
… is an option to Altivar ATV61 and ATV71 range
Schneider Electric 3 - Engineered Drives - Martin Gradner – March 2009
Application examplesGantry crane
Water pump
Downhill conveyors
Escalators
Fans
Supply pumps
Schneider Electric 4 - Engineered Drives - Martin Gradner – March 2009
Two main fields of application
● Hoisting ● Downhill conveyors ● High inertia and high dynamic applications● Test stands● Winches
Regenerative operation
● Weak mains supply● Utilization of full transformer power● Generator supply● Compliance to IEEE 519● Unstable mains conditions
Harmonic mitigation
Schneider Electric 5 - Engineered Drives - Martin Gradner – March 2009
AFE – some technical basics I
t
t
motor cos =1
t
t
generator cos = -1
L1 UL2 VL3 W
Intelligent Rectifier+ Line Filter
InverterIGBT bridge
Schneider Electric 6 - Engineered Drives - Martin Gradner – March 2009
AFE – some technical basics II
● AFE works like a step up chopper
● AFE changeover from motor to generator operation shock-free
● AFE has a sinusoidal mains current
● AFE always needs line filter components
Schneider Electric 7 - Engineered Drives - Martin Gradner – March 2009
Components of the AFE
LFM – Line Filter Module
LFC – Line Filter Choke
AIC – Active Infeed ConverterAFE
AIC Active Infeed Conv. INV InverterLFM Line Filter Module
LFC Line Filter Choke
Schneider Electric 8 - Engineered Drives - Martin Gradner – March 2009
AFE used for braking - Arguments I
Easy to use braking solution for energy efficient operation
Continuous nominal braking power and overload capability
Sinusoidal mains current in all operating states
Constant Power factor 1 in all operation modes
Mains voltage drops up to 40% without interruption of operation
Standard distribution transformer can be used
Wide mains frequency range (30 -70 Hz)
Schneider Electric 9 - Engineered Drives - Martin Gradner – March 2009
AFE used for braking - Arguments II
● No additional high temperature heat source like with resistor braking
● Adjustable braking torque and braking power
● Adjustable fast deceleration ramps
● Resistor braking for emergency operation possible
● Integrated RFI filter, class C3
● Mains short circuit power up to 100kA
Schneider Electric 10 - Engineered Drives - Martin Gradner – March 2009
Braking options overview
0,75 90/110 630/800 kW200/250
Braking Solution
Braking unit + resistor
Network braking unit
Active Front End
Recommendeddepending on application
Available rangedepending on application
2.400
Schneider Electric 11 - Engineered Drives - Martin Gradner – March 2009
AFE used for harmonic mitigation - Arguments
Easy to use solution for optimum harmonic mitigation
THDi less than 4% in all operating states
Constant Power factor 1 in all operation modes
Mains voltage drops up to 40% without interruption of operation
Integrated RFI filter, class C3
Wide mains frequency range (30 -70 Hz)
Mains short circuit power up to 100kA
Operation at weak mains supply
Operation at diesel generator supply
Schneider Electric 12 - Engineered Drives - Martin Gradner – March 2009
Harmonic mitigation overview
0,75 90/110 630/800 kW200/250
HarmonicMitigation Solution
Passive filter
Active filter
Multi pulse solution
Recommendeddepending on application
Available rangedepending on application
2.400
Active Front End
Schneider Electric 13 - Engineered Drives - Martin Gradner – March 2009
Application setup
1 : 1 - Application
One AFE+
One Inverter
“4Q Drive”“LH Drive”
1 : n - Application
One AFE+
several Inverter
“DC – Bus”
n : n - Application
several AFE+
several Inverter
“Parallel AFE”
Schneider Electric 14 - Engineered Drives - Martin Gradner – March 2009
1 : 1 - Application
One Active Front End for one Inverter● Same size for AIC and INV full power for both energy directions● AIC and inverter are simply connected via +/- terminals
Schneider Electric 15 - Engineered Drives - Martin Gradner – March 2009
1 : n - Application
One AFE supplies a common dc-busfor several drives:
● One single mains supply for all drives within a machine/process
● Size of AFE for real power consumption only● Total Inverter power can be up to 4 times the
nominal power of the AFE
Schneider Electric 16 - Engineered Drives - Martin Gradner – March 2009
n : n - Application
AFE can operate in parallel for supply of a common dc-bus:
● Enables process setup● Used for safety reasons
(redundancy)● Used to increase the supply
power of AFE● Used to “standardize” the
size of AFE● Used to reduce numbers of
spare parts
Schneider Electric 17 - Engineered Drives - Martin Gradner – March 2009
AFE Control concepts
Control of AFE can be done in several ways:
● Auto start
● Control via digital I/Os
● Control via inverter field bus
● Control and monitoring via CANopen or Modbus
● Control and monitoring via field bus (communication bridge)
Schneider Electric 18 - Engineered Drives - Martin Gradner – March 2009
Energy efficiency, Example
● Container crane hoisting application, 250 kW load,
cycle time 5 min., operation time: 8h/day, 200 days/a
(1 min. lifting, 1 min. lowering, 3 min. handling)
Energy cost: 0,12 €/kWh
Drive investment for resistor braking: 23.000 €
Drive investment for AFE solution: 34.000 €
● Result
Energy consumption with resistor braking: 100.000 kWh / a = 12.000 €
Energy consumption with AFE: 40.000 kWh / a = 4.800 €
Energy and cost savings: 60.000 kWh / a = 7.200 €
Payback time: ~ 1,5 years
Schneider Electric 19 - Engineered Drives - Martin Gradner – March 2009
● Easy to install● Mains contactor
● 24V control supply
● Charging circuit
● Charging fuses
● Charging circuit breaker
● Charging resistors
● Fan supply for AIC and INV
● High efficiency due to new control structure● No damping resistors
● Reduced losses of LFM
● No voltage sense lines
● Operation independent of phase sequence
Altivar AFE Technical advantages
Integrated in LFM
Schneider Electric 20 - Engineered Drives - Martin Gradner – March 2009
● Hardware consistency● Same design of AIC and INV
● Same HMI as for ATV61/71
● Reduce projecting and mounting time
● 90% of spare parts are identically
● Easy servicing
● Same quality
● Quality and Delivery convenience● Assembly on the same production line
● Same delivery performance
● Available also in enclosed version
AFE Commercial advantages
Schneider Electric 21 - Engineered Drives - Martin Gradner – March 2009
● Complete AFE consist of 3 components only● Easy to project● Simple to mount● Reduce time for wiring
● Practically no limits for mains short circuit capability● Minimum mains short circuit capability not required● Maximum mains short circuit capability 100kA
(7 MVA transformer @ 690V)
● Full integration in Engineered Drives offer● Customised solutions● 100% tested functionality● Optimised size● High protection degree
AFE Competitive advantages I
Schneider Electric 22 - Engineered Drives - Martin Gradner – March 2009
● Novel LFM design without damping resistors● Patent pending● Reduce losses● Reduce components● Increase energy efficiency
● EMC level C3 as standard● All components build in● Easy to project● Reduce installation time● Provides safe operation
● Easy to wire, AIC cables are pre-assembled● Fan supply cable● Control cables
AFE Competitive advantages II
Schneider Electric 23 - Engineered Drives - Martin Gradner – March 2009
Product certification / specifications
● Product certification● CE marking according to the low voltage directives (73/23/EEC) and to the
EMC directives (89/336/EEC)
● UL and CSA pending
● EMC emission:● Conducted and radiated emissions in accordance to product standard IEC
61800-3 Category C3 (EN 55011-Class A Group 2)
● Harmonic emission:● Compliance to all actual relevant regulations and standards as e.g.:
● IEC 61800-3
● IEEE 519
● ER G5/4-1
( )
Schneider Electric 24 - Engineered Drives - Martin Gradner – March 2009
400V class - Specification
● Line voltage:380V … 400V +/-10% (-30% for less than 1 min.) for TT-, TN- or IT-mains
440V … 480V +/-10% (-40% for less than 1 min.) for TT-, TN- or IT-mains
● Line frequency:50/60Hz +/-5% (30 to 70Hz time-limited or with separate supply for the fans)
● Nominal DC-link voltage: 650V DC for mains voltage 3AC 380V/400V
720V DC for mains voltage 3AC 440V
770V DC for mains voltage 3AC 480V
● Overload:120% for 60s every 10 minutes
● Protection degree: IP00, enclosed drives: IP23/IP54/IP54SA
Schneider Electric 25 - Engineered Drives - Martin Gradner – March 2009
690V class - Specification
● Line voltage:500V … 525V +/-10% (-20% for less than 1 min.) for TT-, TN- or IT-mains
600V +/-10% (-30% for less than 1 min.) for TT-, TN- or IT-mains
690V +/-10% (-40% for less than 1 min.) for TT-, TN- or IT-mains
● Line frequency:500V … 525V: 50Hz +/-5%
600V/690V: 50/60Hz +/-5% (30 to 70Hz time-limited)
● Nominal DC-link voltage: 840V DC for mains voltage 3AC 500V/525V
960V DC for mains voltages from 3AC 575/600V
1100V DC for mains voltage 3AC 690V
● Overload: 120% for 60s every 10 minutes
● Protection degree: IP00, enclosed drives: IP23/IP54/IP54SA
Schneider Electric 26 - Engineered Drives - Martin Gradner – March 2009
Name and Ordering
Name: AFE ●●●V ●●●kWDC power: 120 … 860 kW
Voltage range: 400 = 400 … 480V
690 = 500 … 690V
Each AFE consists of 3 mandatory components, which have to be ordered separately:
Name: AIC - ●V●●● VW3 A7 ●●●LFM - ●V●●● VW3 A7 ●●●LFC - ●V●●● VW3 A7 ●●●
DC power: 120 … 860 kW
Voltage range: 4 = 400 … 480V
6 = 500 … 690V
Schneider Electric 27 - Engineered Drives - Martin Gradner – March 2009
AFE – Altivar allocation 1:1, 400V
INV (Inverter)Powerin kW AFE-Sizes
ATV71 ATV61 CT VT 400V
- ATV61HD90N4D - 90 400V 120kW
ATV71HD90N4D ATV61HC11N4D 90 110 400V 120kW
ATV71HC11N4D ATV61HC13N4D 110 132 400V 145kW
ATV71HC13N4D ATV61HC16N4D 132 160 400V 175kW
ATV71HC16N4D - 160 - 400V 240kW
- ATV61HC22N4D - 220 400V 240kW
ATV71HC20N4D ATV61HC25N4D 200 250 400V 275kW
ATV71HC25N4D ATV61HC31N4D 250 315 400V 340kW
ATV71HC28N4D - 280 - 400V 430kW
ATV71HC31N4D ATV61HC40N4D 315 400 400V 430kW
ATV71HC40N4D ATV61HC50N4D 400 500 400V 540kW
ATV71HC50N4D ATV61HC63N4D 500 630 400V 675kW
CT … constant torque
VT … variable torque
Schneider Electric 28 - Engineered Drives - Martin Gradner – March 2009
INV (Inverter)Powerin kW AFE-Sizes
ATV71 ATV61 CT VT 690V
ATV71HC11Y ATV61HC13Y 110 132 690V 145kW
ATV71HC13Y ATV61HC16Y 132 160 690V 175kW
ATV71HC16Y ATV61HC20Y 160 200 690V 220kW
ATV71HC20Y ATV61HC25Y 200 250 690V 275kW
ATV71HC25Y ATV61HC31Y 250 315 690V 340kW
ATV71HC31Y ATV61HC40Y 315 400 690V 430kW
ATV71HC40Y ATV61HC50Y 400 500 690V 540kW
ATV71HC50Y ATV61HC63Y 500 630 690V 675kW
ATV71HC63Y ATV61HC80Y 630 800 690V 860kW
AFE – Altivar allocation 1:1, 690V
CT … constant torque
VT … variable torque
Schneider Electric 29 - Engineered Drives - Martin Gradner – March 2009
References400V AFE-Sizes Components Component-
References
400V 120kW AIC-4V120:LFM-4V120:LFC-4V120:
VW3 A7 250VW3 A7 260VW3 A7 265
400V 145kW AIC-4V145:LFM-4V175:LFC-4V175:
VW3 A7 251VW3 A7 261VW3 A7 266
400V 175kW AIC-4V175:LFM-4V175:LFC-4V175:
VW3 A7 252VW3 A7 261VW3 A7 266
400V 240kW AIC-4V240:LFM-4V340:LFC-4V340:
VW3 A7 253VW3 A7 262VW3 A7 267
400V 275kW AIC-4V275:LFM-4V340:LFC-4V340:
VW3 A7 254VW3 A7 262VW3 A7 267
400V 340kW AIC-4V340:LFM-4V340:LFC-4V340:
VW3 A7 255VW3 A7 262VW3 A7 267
400V 430kW AIC-4V430:2 x LFM-4V340:2 x LFC-4V340:
VW3 A7 2562 x VW3 A7 2622 x VW3 A7 267
400V 540kW AIC-4V540:2 x LFM-4V340:2 x LFC-4V340:
VW3 A7 2572 x VW3 A7 2622 x VW3 A7 267
400V 675kW AIC-4V675:2 x LFM-4V340:2 x LFC-4V340:
VW3 A7 2582 x VW3 A7 2622 x VW3 A7 267
690V AFE-Sizes Components Component-References
690V 145kW AIC-6V145:LFM-6V220:LFC-6V220:
VW3 A7 270VW3 A7 263VW3 A7 268
690V 175kW AIC-6V175:LFM-6V220:LFC-6V220:
VW3 A7 271VW3 A7 263VW3 A7 268
690V 220kW AIC-6V220:LFM-6V220:LFC-6V220:
VW3 A7 272VW3 A7 263VW3 A7 268
690V 275kW AIC-6V275:LFM-6V430:LFC-6V430:
VW3 A7 273VW3 A7 264VW3 A7 269
690V 340kW AIC-6V340:LFM-6V430:LFC-6V430:
VW3 A7 274VW3 A7 264VW3 A7 269
690V 430kW AIC-6V430:LFM-6V430:LFC-6V430:
VW3 A7 275VW3 A7 264VW3 A7 269
690V 540kW AIC-6V540:2 x LFM-6V430:2 x LFC-6V430:
VW3 A7 2762 x VW3 A7 2642 x VW3 A7 269
690V 675kW AIC-6V675:2 x LFM-6V430:2 x LFC-6V430:
VW3 A7 2772 x VW3 A7 2642 x VW3 A7 269
690V 860kW AIC-6V860:2 x LFM-6V430:2 x LFC-6V430:
VW3 A7 2782 x VW3 A7 2642 x VW3 A7 269
Schneider Electric 30 - Engineered Drives - Martin Gradner – March 2009
List of abbreviations
AFE … Active Front End (consists of LFM+LFC+AIC)
LFM … Line Filter Module (part of AFE)
LFC … Line Filter Choke (part of AFE)
AIC … Active Infeed Converter (part of AFE)
INV … Inverter
THD … Total Harmonic Distortion
EMC … Electromagnetic Compatibility
CT … Constant Torque
VT … Variable Torque
NBU … Network braking unit
4Q … 4 quadrant (operation)
LH … Low harmonic
Schneider Electric 31 - Engineered Drives - Martin Gradner – March 2009
Make the mostof your energy
Schneider Electric 32 - Engineered Drives - Martin Gradner – March 2009
More technical details …