Converteam Ltd West Avenue Kidsgrove ST7 1TW United Kingdom Tel : +44 (0)1782 781000 Fax : +44

(0)1782 781001 Boughton Road, Rugby Warwickshire CV21 1BU United Kingdom Tel: +44 (0)1788 563563 Fax: +44 (0)1788 560767

a Converteam Group company

www.converteam.com

MV3000e
Active Energy Management

- CONVERTEAM - 2007. Publication HH-MV3000AEM-12/06. CONVERTEAM, the CONVERTEAM logo and any alternative version thereof are trademarks and service marks of CONVERTEAM. The other names mentioned, registered or not, are the property of their respective companies.

MV3000e AEM Configuration

Mains Bridge

Machine Bridge

3 Phase Supply Line Contactor

Input Filter

3 Phase Induction Motor

MV3000e

MV3000e

Converteam
The MV3000e - Active Energy Management (AEM) range of variable speed AC Drives implement the latest low harmonic technology in the form of two identical IGBT bridges, giving full four quadrant control. A controlled IGBT input bridge replaces the conventional diode bridge to give a near sinusoidal supply current during both motoring and regeneration. MV3000e AEM therefore provides a single solution to relieving the increased pressures on industry to both improve process efficiency in the face of increasing energy costs and reduce mains supply harmonics where pre-existing distortion is at its limit.

Active Energy Management

The advantages of having a fully controlled input bridge are:

Virtually zero harmonic distortion of the supply current Physically smaller and lower cost than a 12 pulse arrangement with transformer Unity power factor on the mains supply Power factor correction from surplus mains bridge capacity High dynamic response The ability to boost input supply to withstand a wider supply voltage variation or increase motor voltage above the supply voltage Automatic energy recovery to the supply with regenerative braking Ability to improve pre-existing supply distortion

MV3000e AEM Configuration

At its basic level, the AEM product is a simple 3-phase bridge called a Bi-directional Converter, which can be configured as either a mains bridge or a machine bridge to enable:
Generation of a controlled DC link voltage when connected to a suitable mains supply, or Control of an AC induction motor when connected to a suitable DC link supply

All other features of MV3000e are retained such as:

Ease of use Comprehensive parameter adjustments Suitable for a wide range of industrial applications Ratings 22kW to 6MW, 380 to 690 V Compact MicroCubicle format plus air and liquid cooled DELTA module versions available up to 6 MW Multi-mode operation including frequency control, open and closed loop flux vector control High plant availability with ridethrough features Communications options 30 parameters for standard applications. Only need to edit 3. Up to 490 for specialised applications and process tuning

Linking two such units together and controlling one as a mains bridge and the other as a machine bridge produces an AEM Drive. The product is set up using the advanced keypad called Drive Data ManagerTM (DDM). This can be fitted into the harbour of the MV3000e unit or panel mounted using the optional mounting kit and remote cable. The AEM drive can be quickly and easily assembled by the user, together with its Converteam supplied input filter, or a complete drive can be purchased assembled in a cubicle, ready to connect to the supply and motor.

MV3000e Active Energy Management Drive with fully controlled input bridge

2 MV3000e Active Energy Management

High Performance - Low Harmonics

Elimination of Dynamic Braking Resistors
The ability to regenerate back into the mains supply makes the MV3000e AEM particularly suitable for use in applications that require a large capacity of dynamic braking. Cranes, high inertia loads such as centrifuges, or applications that are in continual regeneration such as downhill conveyors can return their energy to the mains supply rather than dissipate it in resistors. Process efficiency is greatly increased by eliminating a source of waste heat.

MV3000e Design Innovation

Power Factor Correction

As well as controlling the input supply current waveform, the MV3000e AEM has the ability to control its input power factor. The drive can operate at unity power factor, or at a power factor that may be controlled dynamically by the user. This eliminates the need for extra power factor correction equipment where users are charged for reactive power consumption. This further means that supply components such as cables, transformers and distribution boards can be smaller, leading to lower capital costs.

Machine Bridge

Common DC Link Scheme

Mains Bridge

Excellent Supply Side Waveforms

MV3000e AEM has the ability to regenerate sinusoidal current to the mains supply with virtually zero harmonic distortion. This reduces the amount of unwanted harmonics being put back onto the mains supply, avoiding the need for filter equipment. The installation of MV3000e AEM presents no problem in areas where pre-existing mains supply harmonics are already at capacity, eliminating the need to make a site survey. MV3000e AEM power quality is extremely good during motoring too, since the current taken from the supply is a sinewave with a very low harmonic content. It offers an improvement in performance as well as size over conventional methods of harmonic reduction such as the 12 pulse configuration. Amazingly, since MV3000e AEM has an active sinusoidal input rectifier, it actually improves mains voltage distortion by absorbing some non-sinusoidal currents.

Wider Supply Voltage Range

An additional feature of the MV3000e AEM is the ability to operate over a wider supply voltage range and it can even operate continuously at a low supply voltage, still providing full motor voltage and therefore continued process performance. Alternatively, a motor can be operated at a voltage even higher than mains supply voltage. This effectively shifts the motor nameplate duty point to give a higher speed and more power.

3 Phase Supply

Input Filter

Line Contactor

3 Phase Induction Motors

MV3000e

Common DC Link

MV3000e MV3000e AEM Input Current & Voltage - Regenerating

Common DC Link Scheme with Several Machine Bridges

Since the mains bridge and machine bridge are not arranged as a single unit, the AEM concept can be extended to include common DC link schemes where a single large rated mains bridge feeds a number of smaller rated machine bridges. One or more machine bridges may draw or regenerate power independently and thereby increase the system efficiency by reducing the current drawn from the mains. For larger systems, where the mains bridge rating exceeds the rating of the MicroCubicleTM range, a larger bridge configuration can be created using the MV3000e DELTA AEM range.

High Performance Mains Bridge Control

In high performance applications where flux vector control may be used, it is important that the input mains bridge and output machine bridge have equal performance. MV3000e AEM achieves this by utilising load power feed forward which synchronises both bridges together at the current control level. The result is that MV3000e AEM can provide all the benefits of low harmonics and four quadrant control in even the most demanding of applications.

Conventional 6 Pulse Diode Bridge - Input Current MV3000e AEM Input Current & Voltage - Motoring

Easy to use High Performance Motor Control

Included within MV3000e AEM is the standard MV3000e range of motor control modes: from simple frequency control for general purpose applications, to closed loop flux vector control for high performance applications. Encoderless flux vector control provides high performance in environments in which encoders may not be suited. Torque control, as well as rotary and linear position control allows the drive to meet the demands of diverse applications as standard. Although containing sophisticated features, MV3000e AEM is extremely easy to set-up and use. Parameters grouped in functional menus, together with a step-by-step quick start guide and auto-tune make MV3000e AEM drives fast to set up. More advanced menus may be accessed for more in-depth features and adjustments. Converteam award winning Drive Data Manager keypad and Drive Coach software provide comprehensive but effortless commissioning.

4 MV3000e Active Energy Management

Features & Benefits

Fully controlled, four quadrant, input bridge
Regeneration back into the supply Energy efficient No need for separate dynamic brake unit or resistor No local ambient heating by dynamic brake resistor Ideal for cranes, downhill conveyors, high inertia loads Energy recovery gives lower operating cost Extremely low harmonic supply current distortion No additional harmonic burden on existing installations Eliminates the need for harmonic filters Better than 6, 12, 18 and 24 pulse drives Ability to improve pre-existing distortion on mains supply waveform Site adjustable between 0.8 lagging to 0.8 leading Unity power factor operation drive looks resistive No up-rating required of supply cables, transformers, distribution equipment No additional power factor correction capacitors needed when adding a drive to an existing installation Can help reduce electricity costs where reactive current is charged Provides system power factor correction from surplus drive capacity Maintained DC link voltage under varying supply voltage conditions Allows full motor performance by maintaining full motor voltage with low or varying supply voltage With normal supply voltage, allows higher motor voltage without field weakening and so higher power than the nameplate rating. This can allow a smaller motor frame size to be used. Single mains bridge for multiple machine bridges on a common DC link scheme provides all the benefits of AEM at the lowest cost Reduced component count and system complexity Frequency control Closed loop flux vector control Encoderless flux vector control Includes encoder loss ride-through feature Matches mains bridge and machine bridge performance to maintain DC link voltage Allows mains bridge to operate at high bandwidth, matching flux vector performance on machine bridge

Product Codes & Ratings

Bi-Directional Converters as Mains Bridges
Converter Model Mains Rating Mains Current 1.1/1.5 O/L (A) DC Link DC Link Voltage (V)

Technical Data
Environmental Storage
Temperature range: Relative humidity: Altitude: -25C to +55C (-13F to +130F) 5% to 90% non-condensing not critical below 40C (104F)

Miscellaneous Data for all Units

Cooling - method: - air quality: Forced air cooled, with internal fans. Clean, free from dust, condensation and conductive vapours (i.e. pollution degree 2 according to IEC 60664-1 and UL840). If optional dirty air kit is fitted, the power devices can use unfiltered air that does not contain corrosive, conductive or explosive dust or gases Complies with EN61800/IEC61800 Part 3 CE marked to comply with the European Union Low Voltage Directive 2006/95/EC EN50178, ANSI/UL508C, CAN/CSA C22.2-14 Drive Data ManagerTM - mounts on drive module, cubicle, or is hand held. Control terminals for remote control (analogue and digital) wiring. Control via Serial Link English, French, German and Portuguese RS485, RS232, with MODBUS ASCII/RTU, GEM80 ESP, CANOpen. Drive to drive link. Ethernet, PROFIBUS, DeviceNet 2 x 12 bit resolution, 10VDC or 20mA 2 x 12 bit resolution, 10VDC or 20mA

400V AC Nominal 50Hz (380 to 440V AC)

MV3071J5A1 MV3140J5A1 71/58 140/105 364/292 475/374 450-850 450-850 450-850 450-850

Sinusoidal input current waveform

MV3364J5A1 MV3566J5A1

Transport
Temperature range: Relative humidity: Altitude: Vibration, drop: -25C to +70C (-13F to +158F) <95% non-condensing not critical below 40C (104F) IEC60721-3-2 Class 2M1 EMC: CE: Safety: Control sources:

480V AC Nominal 60Hz (440 to 480V AC)

MV3071J5A1 MV3140J5A1 65/52 124/96 302/240 460/365 450-850 450-850 450-850 450-850

Adjustable input power factor

MV3364J5A1 MV3566J5A1

Operating
Temperature range: Relative humidity: Altitude: Vibration: Cooling air (pollution & dust) Ingress protection: 0C to 40C (+32F to +104F); 40C to 50C (+104F to +122F) with derating 5% to 95% non-condensing 1000m, 1000m to 2000m with derating IEC60721-3-3 CLASS 3MI & EN50178 Pollution degree 2 (IEC60664-1, UL840, CSA C22.2 No. 0.2-93) IP20 (NEMA 1). Loose items are IP00 (unprotected). IP21 with Drip Option

600V AC Nominal 60Hz (480 to 600V AC)

MV3099J6A1 MV3242J6A1 MV3382J6A1 99/77 242/192 280/234 600-1100 600-1100 600-1100

690V AC Nominal 50Hz (440 to 690V AC)

MV3099J6A1 MV3242J6A1 MV3382J6A1 98/82 211/170 272/221 600-1140 600-1140 600-1140

Languages: Serial communications: Analogue inputs:

Voltage step-up facility

Electrical Data for Mains Bridge

Spectrum Table
Harmonic Order
1 5 7 11 13 17 19 23 25 29 31

Modular building blocks Multi-mode motor control

Percent of Fundamental current

100 0.67 0.36 0.11 0.04 0.03 0.06 0.09 0.31 0.05 0.02

12 pulse % of Fund
100 1.00 0.69 8.35 4.52 0.29 0.29 1.99 1.69 0.17 0.16

AEM % of Fund
100 1.6 1.0 0.3 0.05 0.4 0.08 0.05 0.07 0.03 0.03

Supply
Standard voltage range: (as selected) Voltage variation: (on voltage range) Frequency: Operational frequency range: Switching frequency: Overload rating: Harmonic currents on the supply: (from a sinusoidal voltage source)

380V AC - 440V (400V nominal) 50Hz 500V AC - 690V AC (690V nominal) 50Hz 440V AC - 480V AC (480V nominal) 60Hz 500V AC - 600V AC (600V nominal) 60Hz 10% long term 15% for 0.15 to 30 cycles no trip 50Hz, 60Hz as selected 45Hz to 63Hz 2.5kHz default. 5, 7.5kHz selectable with derating 150% or 110% FLC for one minute 6 times per hour Less than 2%

Analogue outputs: Digital inputs: Digital outputs:

6 configurable, 1 fixed, 10 - 50 VDC 3 x C/O relays. All configurable. Additional input and outputs through the CANOpen interface 1 x RS422 Programmable as: frequency input for speed reference or frequency output of motor speed 4 channel differential line receiver for incremental encoder (A, A*, B, B*, Z, Z*). Max 1 MHz Frequency: Resolution: 0.01%, Control Accuracy: 0.1%. Speed: Resolution: 0.01%, Accuracy (absolute) 0.01% Complies with EN 61800-2 (IEC 61800-2) and EN 60146-1-1 (IEC 60146-1-1) 0VVVF 0 0 Encoderless 0Flux Vector Flux Vector 0with Encoder 0
50:1 20 Rad/s >500 Rad/s 10% 0.5% >1000:1 100 Rad/s >500 Rad/s 5% 0.02%

High speed digital I/O:

Load power feed-forward

Encoder feedback: Performance:

Ratings performance data for machine bridges

NOTE: Spectrum measured with a pure sinewave supply

Electrical Data for Machine Bridges

Bi-Directional Converters as Machine Bridges*
Converter Model DC Link Voltage DC Link Current (A) Motor Rating Nominal Power 1.1 O/L (kW) 1.5 O/L (kW) Nominal Power 1.1 O/L (HP) 1.5 O/L (HP) Drive Output Current Continuous Current (Maximum Current) 1.1 O/L (A) 1.5 O/L (A)

DC supply voltage range:

400V AC Nominal 50Hz (380 to 440V AC)

MV3071J5A1 MV3140J5A1 MV3364J5A1 MV3566J5A1 450 - 850 450 - 850 450 - 850 450 - 850 88/72 176/130 462/370 672/552 37 75 200 309 30 55 160 248 50 101 268 413 40 74 214 330 71 (78) 140 (154) 364 (401) 556 (576) 58 (87) 105 (158) 292 (438) 407 (611)

Voltage variation: Frequency: (optimised) Operational frequency range: Switching frequency: Overload rating:

450V - 850VDC for 400V AC 50Hz or 480V AC 60Hz nominal outputs 600V - 1100VDC for 600V AC 60Hz nominal outputs 600V - 1140VDC for 690V AC 50Hz nominal outputs 10% long term, 15% for 0.5 to 30 cycles with loss of performance but no trip 50Hz, 60Hz as selected 45Hz to 63Hz 1.25kHz default. 2.5, 5, 7.5kHz selectable with derating 150% or 110% FLC for one minute 6 times per hour

Ratings/ Performance 0 0
Speed control range Speed control bandwidth Torque control bandwidth Torque control accuracy Speed control accuracy

50:1 N/A <1 Rad/s 10% 1%

480V AC Nominal 60Hz (440 to 480V AC)

MV3071J5A1 MV3140J5A1 MV3364J5A1 MV3566J5A1 450 - 850 450 - 850 450 - 850 450 - 850 81/65 159/120 391/314 673/526 37 75 187 364 30 56 149 291 50 100 250 486 40 75 200 388 65 (72) 124 (137) 302 (332) 516 (568) 52 (78) 96 (144) 240 (360) 400 (601)

600V AC Nominal 60Hz (480 to 600V AC)

MV3099J6A1 MV3242J6A1 MV3382J6A1 600 - 1100 600 - 1100 600 - 1100 127/96 314/252 460/369 75 187 309 56 149 249 100 250 412 75 200 332 99 (109) 268 (252) 352 (387) 77 (116) 192 (288) 284 (425)

Overall Dimensions (millimetres)

Bi-directional Converter MV3071J5A1 Height 620 809 893 1170 Width 170 255 430 485 Depth 350 370 420 450 Weight (kg) 27.0 45.0 100.5 170.0

690V AC Nominal 50Hz (440 to 690V AC)

MV3099J6A1 MV3242J6A1 MV3382J6A1 600 - 1100 600 - 1100 600 - 1100 122/102 268/215 435/400 90 200 342 75 160 276 121 268 456 101 214 368 98 (108) 211 (232) 339 (373) 82 (123) 170 (255) 273 (410)

MV3140J5A1 - MV3099J6A1 MV3364J5A1 - MV3422J6A1 MV3566J5A1 - MV3382J6A1

*Conventional MV3000e MicroCubicle drives may be used as machine bridges to provide intermediate ratings. For larger ratings up to 6000kW, contact us for details of air and liquid cooled DELTA units.

6 MV3000e Active Energy Management