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INDUSTRIAL POWER CONSIDERATIONS FOR VARIABLE SPEED DRIVES (VSD's)

James M.Hoelscher
ABSTRACT Electronic variable speed drives (VSD's) are the preferred choice for industrial AC motor speed control. Offering many advantages over their mechanical counterparts, the VSD's can provide improved efficiency and flexibility, enhanced product quality, a higher degree of accuracy and computer compatibility. However, they are more sensitive to power line disturbances such as transients, harmonics, voltage variations and momentary interruptions. These concerns must be addressed at the time a VSD installation is designed and installed in order to avoid future problems with both the VSD and other plant electronic equipment. Undervoltages are also commonly referred to as "brownouts" and most are intentional by the utility to extend system capacity during heavy load conditions. Overvoltages are generally caused by poor line regulation during light loads. Surges and sags - These are special short term cases of undervoltage and overvoltage conditions generally exceeding allowable limits for some significant portion of a cycle. These voltage fluctuations are usually of larger amplitude and of a shorter duration than undervoltages and overvoltages. Transient impulses - These are deviations from the ideal AC sine wave of very short duration and typically last from a fraction of a microsecond to a few milliseconds. The amplitude of the transients is such that they greatly increase or decrease the instantaneous voltage. Increases are also referred to as voltage "spikes" and decreases are referred to as "notches". Dropouts and line interruptions - Voltage decreases down to zero volts are called "dropouts" and usually last only a portion of a cycle. These are generally caused by utility breakers opening and closing in the presence of a fault condition. When the power system is removed for a more significant period of time, these "line interruptions" usually represent a serious utiliiy problem. Frequency variations - Defined as deviations of + or .5 Hz or less of input line frequency (This is seldom a problem in the U.S.)

I. INTRODUCTION
In the U.S. it is customary for most large industrial facilities to be supplied with a three phase source of electrical power at a frequency of 60 hz. The most common user voltage is 460VAC and matches the nameplates of most AC induction motors. AC induction motors being the most common type of load. Normally, plant distribution systems are either the four wire "wye" with ground or the grounded and ungrounded "delta".

Each of these types of power systems are susceptible to line disturbances which may be introduced via the utility's transmission lines or generated internally within the user's own facility. Most power line disturbances are voltage rather than frequency related. Several of these voltage disturbances are explained here. Undervoltage and overvoltage - RMS voltage fluctuations that exceed allowable limits for more than 2.5 seconds.

Presently acceptable limits vary from state to state and no national standards are presently set. Consult your utility company for data and an analysis of your

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power system. 11. LINE TRANSIENTS Transients are variations from the normal AC sine wave having very short duration as compared with one cycle typically from nanoseconds to milliseconds. The transients range from single pulses with sharp rise times and progressive decay to oscillatory disturbances lasting for five to ten cycles within a gradually decaying window. They may either increase or decrease the instantaneous magnitude of the AC sine wave and are defined as a "spike" or "notch", respectively.

are typically the result of connecting or disconnecting heavy loads or power factor correction capacitors to the line. These transients exhibit decaying oscillatory characteristics at frequencies up to and above 5 KHZ. Both common mode and normal mode transients are shown in Figure 1. It is important to know the type of transient since the methods of suppressing them are different.

Line transients can range in magnitude from a fraction of peak voltage up to hundreds or thousands of volts and by far cause the largest voltage swings of any types of line disturbances. Note from Figure 1 that transient magnitude is measured from the point it occurs on the sine wave and not from zero voltage. Because of this, the proper way to examine a transient disturbance is to block out the sine wave so that the transient appears by itself. It is also important to know the source and direction of a transient. Was it generated in the VSD or arrive via the power line? Either is possible, and, of course, the solutions to the two problems are very different. There are two types of transients: common mode transients where the voltages to ground of the AC power line phases rise and fall together, and normal-mode transients where the phase-to-ground voltages vary from phase to phase. Common mode transients are caused by such things as lightning or utility breaker tripping and closure and usually result in single spikes or notches on the AC sine wave. In contrast, normal mode transients

L-L

Figure 1. Transient Disturbance 111. TRANSIENT OVERVOLTAGE CONCERNS ASSOCIATED WITH CAPACITOR SWITCHING
8

Transient overvoltages are always a concern when power factor correction capacitor switching is involved. Each time a capacitor is energized, a transient oscillation occurs between the capacitor and the system inductance. The result, (see Figure 2), is a transient overvoltage which can be as high as 2.0 per unit (of the normal voltage) at the capacitor location. The magnitude is usually less than 2.0 per unit due to damping provided by system loads and losses. The transient over voltage caused by energizing

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capacitors is generally not a concern to drive manufacturers because they are usually below the level at which surge protective devices operate (1.5 - 2.0 per unit). A much more severe situation occurs when there are larger capacitors switched on the power line and lower voltage capacitors have been added within the customers facility. The simplified circuit of concern is shown in Figure 3.
4

OTHER FEEDERS

OlSTRlBUTKXl FEEOER

CUSTOMER TRANSFORMER

P
Figure 3.

SUBSTATION

E$ClTOR
CAPACITORS

LOAD

(V5o.r)

- 2 3

I
AC circuit for problems with

L o

z 0

transient magnification.

voltage

-2
-4

L
0.00

I
0.02

I 0.04
Time (Seconds)

I
0.06

I
0.08

The magnification of capacitor switching transients is most severe when the following conditions exist:

Figure 2.

Capacitor bank transient.

energizing

- The capacitor switched on the higher voltage system is much larger (KVAR) than the capacitor at low voltage bus.
- The frequency of oscillation (fl.) which occurs when the high voltage capacitor that is energized is close to the resonant frequency (a) formed by the step-down transformer in series with the low voltage capacitor (fl =
f2)

When the frequency of a transient overvoltage matches the series-resonant frequency of the customers transformer coupled with the customers capacitor(s), a low impedance, high current condition results. As this high current passes through the transformer, it induces a large voltage potential that crosses through zero voltage to create a large voltage of opposite sign at the resonant frequency. The VSD and the customers paralleled capacitor(s) (and their surge protection devices) then see this magnified voltage (compared to distribution feeder voltage). When the resonant frequency current completes its path to ground through the capacitor, the voltage experiences a boost in respect to the ground reference voltage.

- There is little damping provided by loads on the low voltage system, as is usually the case for industrial plants.
The transients that occur at the low voltage capacitors are normally in the range of 2.0 to 4.0 per unit. These transients are likely to cause the failure of protective devices and electronic components (SCRs, power diodes, power darlington transistors). VSDs are specifically vulnerable to these transients because of the relatively low

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peak inverse voltage (PIV) ratings of the semiconductor devices and the low-energy of the metal-oxide varistors (MOVs) used to protect the VSD power devices. These magnified transient overvoltages can be controlled in a number of ways:

in the 1 to lo00 HP ranges with either voltage source inverter (VSl) or pulse width modulated (PWM) outputs, typically require a smoothing of tbc DC bus voltage, with a large capacitor bank, for proper operation (Sec Figme 4).

- The capacitor switching transient can


be controlled by using vacuum switches with synchronous closing control to energize the capacitor bank.

L1

Provide high energy MOV protection on the 480V buses. The energy capability of these arresters should be at least several K-Joules.

L2 L3

- Use tuned filters for power factor


correction instead of using only shunt capacitor banks. The tuned filters change the response of the circuit and usually prevent magnification from being a problem. Something that cannot be overlooked is the variable speed drives (VSDs) capability to withstand voltage transients. The semiconductor devices used on the power side of the VSD are normally only rated for a PIV of 1200 to 1400 volts. On a typical power distribution system this PIV rating figures to approximately 170 to 250% of normal system voltage. To protect against line transients, most drive manufacturers will incorporate on-board MOVs for protection. MOVs are typically more effective for many low-energy transients, but when faced with a magnified voltage transient (i.e. power factor capacitor switching) they can be completely destroyed. While the drive susceptibility or sensitivity to transient disturbances is a function of the semiconductor device rating, it may also be related to the drive topology. Drives,

Figure 4.

Simplified diagram of the rectifier circuit showing the DC smoothing capaator stage.

For protection of the VSD components,the DC bus voltage is monitored and the drive is tripped when it exceeds a preset level. In most cases, the level is approximately 158 to 172% of a 480 volt input line voltage. Since the capacitor bank is essentially connected across each of the three phases on the input line, drives of this type can be extremely sensitive to overvoltages on the AC power input side. A current transient, (see Figure 5), resulting from the overvoltage is conducted through the rectifier to the DC bus, sharply raising the DC voltage (See Figure 6) above the operational level and tripping the VSD. This type of nuisance tripping is normally associated with power factor capacitor switching, since it is a very common source of overvoltages on the power distribution system.

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When a 3-phase line reactor is used in conjunction (in series with the AC input line) with an AC VSD, the magnitude of the input current surge is limited, and the capacitor bank charges more slowly. If the line reactor impedance is properly selected, the capacitor voltage will not reach trip levels within the surge time length. The required line reactor size is a function of surge magnitude and duration, distribution system impedance, drive trip level, and specific drive design. Experience indicates that line reactors of 1.5% or 3% reactance will eliminate most overvoltage trips. Note,however, that line reactors are much less effective on AC drives that do not contain large capacitors on the DC bus. The application of line reactors is suggested under the following conditions: an overvoltage fault indication and the normal measured line voltage is within the drive rating. (Most AC drives will indicate the cause for shutdown.)
0.04

Figure 5.

Current surge in VSD as a result of capacitor energizing.

- The VSD periodically trips with

0.05

0.06

0.07

0.08

0.09

0.10

- VSD shutdowns occur at about the


same time of day, usually early morning or late afternoon. (These are the times when capacitors on the power line are usually switched in response to changing load conditions.)

Time (Seconds)

Figure 6. IV.

DC bus voltage capacitor energizing.

during

REDUCING NUISANCE TRIPPING DUE TO CAPACITOR SWITCHING TRANSIENTS

- The VSD

has periodically faulted with damage to the input diodes.


OF LINE

V. THE BENEFITS IMPEDANCE

The best or most efficient way to eradicate nuisance tripping of VSDs is to isolate them from the power line with series line reactors or line isolation transformers.

f f of the When many VSDs are powered o same AC lines, a certain degree of cross talk is injected by the VSDs themselves.

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This reduces the probability of trouble free operation. This interference is in the form of "spikes', "notches", or harmonics superimposed on the power line wave form. When DC VSD's are involved, transients produced by the switching of the power devices are usually absorbed by a snubber circuit designed into the VSD. In most DC VSD's, this consists of a capacitor and resistor connected in series across the switching device. To successfully suppress these transients, each snubber circuit relies on a certain amount of inductance offered by the power wiring, providing a tuned L-R-C filter. It is the inductance that chiefly limits the rate of rise of voltage that is impressed across the device.
With many DC VSD's on the same AC power lines, insufficient inductance is offered by the power wiring to limit the rate of change of voltage, dv/dt. If this dvldt value is high enough to exceed the specification's of the SCR, the result is the misfiring of the device and a resultant nuisance trip, if not the loss of fuses, or damage to the SCR's. This calls for additional inductance to be inserted into the lines. This could take the form of either an isolation transformer if isolation is preferred, or a line reactor, if isolation is not necessary. The value of the required additional inductance of this transformer or line reactor can be calculated (contact Warner Electric/SECO for appropriate specifications), depending upon the line voltage, the snubber circuit components and the specifications of the switching devices.

significant benefits in using power factor correction capacitors, there arc a number of important concerns which should be evaluated when the capacitors arc applied. These concerns require particular evaluation to avoid possiile damage to the VSD's located on the samc power lines.

VI.

HARMONIC PROBLEMS

Harmonics generated by the nonlinear y s t e m can distort loading of the power s both the current and voltage wave forms. Harmonically distorted load currents produce some voltage distortion as they flow through the source impedance. This voltage distortion is g e d y low when the source impedance is I d l percentage of the load impedance. A major source of harmonics U found in both AC and DC drives due to the requirement of rectifying tht AC power. While this is also true of many other loads such as computer power supplies. These power requirements arc much lower than that required by the motar controller. The modern day DC drive controller (employing six pulse phut controlled rectification and connected to a motor of the correct power design code) produces a very well defined harmonic current distortion on the power source. (See Figure 7). However this harmonic current distortion is displaced fiom the system voltage by a power f a c t a that varies closely with speed. DC drives should always be geared to run at tbe base speed or the field-weakened speed of the motor for the best possible power factor. Today's AC drive controller ranges from 1 through 250 HP and k normally a PWM type AC output fed from an AC rectified o this type of voltage source. The input t

The clear conclusion is that the application of power factor correction capacitors, in an electronic VSD environment, must be assessed very carefully. Regardless of the

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Line notching is a well-known phenomenon associated with AC to DC conversion equipment operating in the continuous conduction mode. In the case of a three phase full converter, the thyristors operate in pairs to convert AC to DC. The load current is switched between the various thyristor pairs six times per AC line cycle. During this switching process, which is known as commutation, a brief short circuit occurs which produces THE05ETlCAL a notch in the line-to-line voltage wave 0 0 x TYPICAL form. As illustrated in Figure 8, two !i primary line notches and four secondary _ _ ones are produced in each line cycle. The o w secondary notches are of lower amplitude 9 9 and are the result of notch reflections from other legs of the bridge. The time . required for the commutation to occur is a 5th 7th 11th 13th 17th 19th 23rd 25th function of source impedance and output ORDER OF HARMONIC current magnitude; this time determines the width of the notch. Notch depth depends on the location of the measurement in the Figure 7. Theoretical and typical values power system. Figure 9 illustrates the of harmonic current for a distribution of AC line impedance in a six-pulse converter. typical plant power system. A notch measurement made at the converter Any solution to a harmonic problem must terminals would indicate a notch depth of be prefaced by a thorough study to approximately zero volts. If L 1 = L2 = determine the frequency and magnitude of L3, the notch depth at Point B would be the harmonics, their source and their effect 66% of the maximum depth due to the on the power system, and whether the voltage division of the three impedances. power system is resonant at or near a harmonic frequency. Note, that the

drive appears capacitive and would have a very low impedance to the power system which would result in very large amplitude current pulses appearing near the peak of the line voltage wave form. Likewise, a very large current distortion would be present. To prevent this, an impedance in the form of an AC line reactor or DC bus choke is used to smooth the rectified AC current and thereby significantly reducing the harmonic current distortion. This type of drive achieves an excellent power factor usually greater than 0.9 which varies little with speed. It is possible to achieve harmonic current levels approaching those as shown in Figure 7 for the DC convertor through proper design.

application of power factor correcting capacitors is especially critical to power systems which have significant harmonic distortion. This practice may cause severe damage to equipment on the power system during periods of switching or resonance with system components. The best solution is to reduce any harmonics at the source if possible.

VII.

LINE NOTCHING

I I:

u lb l

0 0

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, LINE-TO-LINE INPUT VOLTAGE

-to

L E E

390

As the line voltage x e c u v c n at the end of a notch, it overshoots and then oscillates or "rings" at the resorrant frtqutncy of the power system. S u & v i a s such as RC snubbers can be used t o dampen these transients, but the suppr#sors can sometimes be ovaworked by the repetitive line notch oscillatiorrr.

Figure 8.

AC voltage wave form for full converter.

Line notching can interfere with the control and/or power circuits of VSD's. If the notch width exceeds the duration of the gate trigger pulse of a thyristor, the device could fail to turn on. This problem can be solved by using wider gate pulses or burst firing, a technique which applies a train of pulses to each thyristor gate. Harmonic voltages and currents associated with line notches can adversely affect the operation of sensitive electronic equipment such as computers and communications equipment. AC line conditioners are available to prevent line voltage irregularities from reaching the sensitive equipment.

o line notching Often the simplest sdution t problems is the addition of chokes or an isolation transformer 011 tbc input of the VSD causing the notching. Thc additional inductance actually makes the notching worse at the drive input, since the notch area increases with incrtased input inductance. However, the notching on the source side of the inductance will be less severe because most of the notch voltage transient will appear across the added inductance. Therefore, the effect of the line notching on othef equipment will be reduced. SUMMARY In conclusion, applying VSD's in an industrial environment can be simplified if the guidelines outlined in this paper are carefully practiced. Tksc techniques can result in improved utility and customer operations and thus a vast improvement in the entire manufacturing process. REFERENCES:

I
FEEDER LINE

1-l

DRIVE La

A+ TO D-C CONVERTER

TRANSFORMER

1. SCR Drives Power Consideration for ASD's GET-6468B.

on REACTOR

Figure9.

AC line distribution.

impedance

2. Power L i n e Considerations for Variable Frequency Drives IEEE transactions on industry applications. VOL 1A-21 NO.5 Sept./Oct. 1985 Jarc and Shieman

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3. Power Quality Considerations for


ASDs. Electric Power Research Institute
4. ASDs in the Process Industry Greg Porter, PSI Energy Power Quality MayNune 1991

James M.Hoelscher Systems Engineering Manager, Warner Electric/SECO BSEET (1988) from the University of North Carolina at Charlotte. Member of IEEE

5. Why Power Factor Correction Capacitors May Upset Adjustable Speed Drives Thomas Grebe, Electro Concepts Power Quality Magazine MayNune 1991

Grateful acknowledgement is given to the following people for their assistance in text and technical advice. James Bums - Senior Project Engineer, W a r n e r Electric/SECO BSEE (1969) from the Milwaukee School of Engineering. Member of IEEE William H.Stokes - Senior Project Engineer, Warner Electric/SECO. BSEE (1971) from North Carolina State University. Member of IEEE

6. Reducing Nuisance Outages With Line Reactors TCI Tech Tips, TCI Issue 1, October, 1991
7. Understanding

Power Line Disturbances Dranetz Technologies Publication

8. IEEE Guide for Harmonic Control and Reactive Compensation of Static Power Converters. IEEE Standard 519, 1981.

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