Danfoss - Andrew Cooper - CII Energy conference - Chennai ... · nVLT® Drive with Passive Harmonic Filter ... The Danfoss LHD is the first of its kind. It ... Danfoss Harmonic portfolio

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| Confidential/Property of Danfoss Drives A/S | Tuesday, 07 September 2010 | 1| Confidential/Property of Danfoss Drives A/S | Tuesday, 07 September 2010 | 1

Danfoss

Presenter: Andrew Cooper

Harmonics –Obstructing energy savings

Focused on climate and energy


Danfoss has solutions ready

nWe have solutions ready for the climate challenge– well-proven technologies with

enormous energy-saving potential

nWe are a global competence centre for energy efficiency– our products and our knowledge are

our key strengths

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Danfoss’ core businessesfocus on Climate & Energy

Power Electronics

n Power modulesn Inverters for Solar & Windn Variable frequency drives

0.18 kW to 1.4 MWn Customized Drive solutions

Refrigeration & A/C Controlsn Mechanical Controlsn Electronic Controlsn Supermarket Servicen Micro Channel Heat

Exchangers

Commercial Compressorsn Commercial Compressorsn Variable Speed Platformsn Turbocor – Joint Venture

Heating Solutions

n Residential Heatingn Electronic Heating Systemsn Hydronic Balancing Controlsn Burner Componentsn Heat Pumpsn Heat Recovery Ventilation

District Energy

n District Energy Controlsn District Energy Stationsn Plate Heat Exchangers


Customized power modules

n A power module is an electronic switchused in power conversion and motion control applications

n Cutting edge technology designed to meet customer requirements

Generating power from the sunn Danfoss develops, produces and

sells solar inverters that are connected to solar cells

n The inverters ensure that up to 98% of the energy available is supplied to the grid

700,000tons is the annual CO2 reductionsaved by the installation of 80,000 inverters in solar powered systems annually

TS16949standard

meets strict Automotive Industry requirements

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VLT® Drives Electronic motor control

n A variable frequency drive (VFD) controls electric motors so they only run at the speed necessary to obtain the desired effect

n Electronic motor control can typically save half the energy in pump and fan applications

n Today, only 8% of all electric motors globally are frequency controlled

n Productsn VFDsn Soft startersn Accessories

26milliontons is the annual CO2 reduction

made by the 2.4 million Danfoss frequency converters installed worldwide


Prospective

Source:

U.S. Energy Information Administration / International Energy Outlook 2010

n The expected Energy consumption increase is 2%/years

n Highest increase in non-OECD countriesdue to increasing living standards

n Increased energy demand will lead to increased production.

n Primary source is coal powered power plants

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Climate challenges

n Due to the present climate challenges, more focus has to be put on production of renewable energy

n Energy conservation is very important

n Energy conserving equipments all have same side effect – Harmonic distortion

n Harmonics obstructing further energy savings

Source: The Journal Science: University Corporation for Atmospheric Research


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2 3

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IDC

VDC

What are Harmonics?

n All diode rectifier circuits draw non sinusoidal currents

n These are referred to as “non linear” loads

n Biggest contributors are:§ Switch mode power supplies§ Light installations§ UPS§ VFD

n Different VFDs have different current waveforms (harmonic footprint)

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Hz50 250 350 550 650 800 950

%

100

THiD=105%THiD=105%

1st 5th 7th 11th 13th 16th 19th Harmonic

RMS=56ARMS=56A

THiD=0%RMS=39A THiD=78,8%RMS=49A THiD=99,8%RMS=54A THiD=103%RMS=55A

Mathematically harmonics are simply the deviation of a pure sinusoidal waveform.

THiD=105%RMS=56A

What are Harmonics?

n Any periodic signal, independent of shape, can be represented as a sum of sine-waves

n This is called a “Fourier” representation

n Current waveform of a VFD can be also be represented as a sinusoidal waveform sum


n You can be sure your supply is already polluted with harmonics.

n Current distortion is less important. Voltage distortion is important to restrict

n Product immunity has to be higher than system distortion to prevent breakdown but product life is a function of distortion level.

n Good engineering practice is to design for a THDv of 5% at the in plant point of coupling= class 1 installation

What’s a safe level of Harmonics?

Imm

unity

leve

l

Max

imum

di

stor

tion

leve

l

10%5% 8%

10%8%5%THvD

Class 3Class 2Class 1IEC 61000-2-4

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At the edge of furtherenergy optimization?

n Applying drives is limited to <30-40%of total system loading. Exceeding this level will lead to:n Equipment trips/stopsn Premature equipment agingn Erratic operation and production stop

n To increase load ability special drives with internal or external harmonic filters are needed.

Example of such are:n VLT® 12-pulse Driven VLT® Low Harmonic Drive n VLT® Drive with Passive Harmonic Filtern VLT® AAF (Advanced Active Filter)


What’s a perfect solution?

n High efficiency

n An equipment that can be turned on/off depending on when needed

n Equipment that does not take up space

n One instead of one each

n Solutions that can also compensate for other grid unfavourable conditions

n Equipment that is reliable

n An easy to use and specify product

n Equipment that can not be overloaded and has long life

n Is free of charge

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What’s a perfect solution?

n Efficiencies of 97% is expected

n Equipment has to be installed in parallel

n Equipment has to be very compact

n One solution to compensate many loads

n Solutions that can also compensate for PF, balance out loads and reduce flicker

n Old technology is better then new

n User-friendly and supporting many different languages

n Equipment that can not be overloaded and has lifetime of 10 years minimum

n Has to be competitive in price


Technological breakthrough takes you higher

n Danfoss own production of 2nd generation IGBT modules have proven its reliability and shown its boundaries since 2005

n A new and faster digital signal processor in the FC-series has allowed faster and more complex calculations in real time

n New and innovative control algorithm from the market leading engineers have improved harmonic control abilities

n Danfoss is proud to present two new mitigation technologies, taking us closer to the ideal :

n The VLT® Active Filtern The VLT® Low Harmonic Drive

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VLT® Active Filter

n The filter cancels distortion by sensing the harmonic currents and injecting currents in counter phase.

n Easy to install and commission

n Easy to retrofit

n Tolerant to load and grid imbalances

n Allows for group compensation, power factor correction and load balance correction

n Ideal for increasing network capacity or generator power

Active Filter

Active filter c/w

with LCL coil

Non- linear loads. E.G.

6 pulse VFD with DC

bus chokes


n 190A – 400A ratings (Up to 4 units can be paralleled for higher rating)

n 380 – 480V, 50/60 Hz (Higher voltage with Auto Transformer)

n <5% THD of rated non-linear load I @ PCCn Overall harmonic mitigation up to 40thn Individual harmonic mitigation 5th – 25th &

power factor correction

n Graphical LCP with data logn Energy saving function via sleep moden Compact IP21 & IP54 enclosures with

segregated heatsink back channel coolingn Optional mains isolator & fuse optional.n EMC filters built inn Coated PCB for extra corrosion protectionn ~90% re-use of VLT® Drive components

potentially reduces sparesn Factory load tested

VLT® Active Filter

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n Central compensation

n Group compensation.

n Individual compensation for High Power Drives. (LHD uses AAF active filter)

VLT® Active filter installation / compensation possibilities


VLT® Active Filters

n The new VLT® Active Filters is installed in parallel and is a flexible choice for compensation of one or multiple loads

n It is built on a 85% drive component reuse ensuring unmatched reliability

n Back-channel cooling reduces electronic contamination and gives prolonged product life

nWith a width of only 600 mm VLT® Active Filters are the most compact solutionavailable

85%Component reuse

ensures unmatched equipment reliability

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VLT® Active Filters

nWith an energy efficiency of 98% the filter is among the most proficient

n The innovative control compensates if needed and goes into sleep if harmonic pollution is low leading to huge energy savings

n Filter offers harmonic compensation, flicker reduction, phase balance, power factor correction and resonance damping

98%Energy efficiency

ensures low running expenses


VLT® Low Harmonic Driven Optimized active harmonic filter connected in

parallel at input of standard VLT drive in single unit

n 132kW – 630kW, 380 – 480V, 50/60 Hzn Harmonic performance <5% THiDn Meets IEEE519 @ short circuit ratios >20 n >0.98 true power factorn Excellent alternative to active front end

drivesn better performance on weak, pre-distorted

or unbalanced suppliesnmotor friendly (compatible with standard

motors complying with IEC60034-17)n high efficiency

n Energy saving function via sleep moden Drive will run if filter sleeps or trips n Compact IP21 & 54 enclosures with

segregated heatsink back channel cooling n EMC filters built in n Coated PCB for extra corrosion protectionn Factory load tested

Example of CURRENT spec.:Fund. 36.0ATHiD <5.0%RMS current 36.2 A

LHD current wave form

LHD voltage wave form

E- Frame LHD

Active filter c/w

with LCL coil

Standard 6 – pulse

VLT Drive

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VLT® Low Harmonic Drive

n Product efficiency of 97% secures the VLT® Low Harmonic Drive pole position for Active harmonic filtration

n The VLT® Low Harmonic Drive ensures 99% energy utilization in the full load range

n High harmonic mitigation is kept even at distortion levels of more then 10%

n Toughest harmonic standards are meetwith this new series of drives

n Compared to other active mitigation solutions the Danfoss LHD is a motor friendly solution. It does not increase insulation and bearing stress like other active mitigation solutions

99%Energy utilazation

The VLT® Low Harmonic Drive keeps true PF close to 1 independent on grid and load conditions


The Danfoss LHD is the first of its kind. It combines the best of three technologies, -the simplicity of the AFE, the performance of an Active filter and drive robustness as a standard 6-pulse diode rectifier drive.

Danfoss LHD´s are:n Easy to specify and installn Comply with toughest harmonic standardsn Load and grid independentn Compactn Efficient and motor friendly

Technology is perfect for:n Getting best performance in very week gridsn Systems with high load dynamicn Critical process application

VLT® Low Harmonic Drive

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Danfoss Harmonic portfolio

Advanced harmonic filters:n Lowest cost for >300kwn Most compact solution for

drives <400An Individual matched for Danfoss

drives to secure performancen Capacitor disconnect optionn Better performance then pulse

drives

12P-drives:n Robust and compact solutionn Offers same advantages as our

High power drives.n Lowest cost >400A

Active Filtersn First Active Filter reusing 85%

drive components which secures unmatched reliability and short lead time

n User friendly and easy commissioning

n Flexible in mounting and setupn Fast enough to reduce flicker

Low harmonic Drivesn First of its kind, to include std

drive and an active filter in one package

n Best harmonic mitigationn Motor friendly n High efficiency

Cen

tral mitig

ation /R

etofit

One o

n o

ne

Passive solutionsActive solutions


VLT® Harmonic Calculation Tool MCT 31n Stand alone mains harmonic calculation

tooln Explorer like project viewn Easy VSD model based selectionn Detailed harmonic report generationn User customized report configuration

Support Tools

PC Software Tool

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We are ready to offer:

n Knowledge and advice about drives and secondary effects

n Freeware calculation tools

n Prompt delivery and support from skilled technicians and sales engineers globally

n A wide harmonic mitigation portfolio of reliable and innovative products. Our high quality product range includes:

n Low Harmonic Drives (A new trendsetter)

n Active Filter (Innovative thinking)

n Passive harmonic filters (Smallest of its kind)

n 12P-drives (A low cost alternative)

Danfoss Drives

Documents

Danfoss - Andrew Cooper - CII Energy conference - Chennai ... · nVLT® Drive with Passive Harmonic Filter ... The Danfoss LHD is the first of its kind. It ... Danfoss Harmonic portfolio