ATV71 - M10 - Network Braking Unit V5 EN

Altivar 71 Training
ATV71_regen-harmonic modules V3 EN
1
26/10/20148 Sept 2004 STIE \ Bertrand Guarinos
Network Braking Units

Summary
ATV71
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26/10/2014 STIE Bertrand Guarinos ATV71_regen-harmonic modules V3 EN
I. The Offer

II. How it works ?

III. Sizing principal

IV. Sizing example

V. Appendix

Summary

Summary
ATV71
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I. The Offer

II. How it works ?


IV. Sizing example

V. Appendix

Summary
ATV71
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Introduction
With ATV71 came a new range of option : the Network Braking Unit

This device allows to regenerate power onto the network when the drive system is
working as a generator.

ATV71 offer is well optimised for duty cycle up to 50% with 5mn braking time

It may replace braking resistors in system witch have quite long generating cycle or
high braking power needs like : hoisting, high inertia machines ..

For such applications, it's a good compromise volume/efficiency/cost.

And the energy saving allows a quick paying off.
Summary
ATV71
5
Offer
Customer benefits
Small compact housing
User friendly first start up, no programming or adjustment necessary
Limitation of the harmonic current regen on the main (line chokes)
DC-bus coupling of several controllers is possible
Up to 4 units can be paralleled (no derating)
DC bus short circuit protection (fuses)
Overload protection during back feed operation
97% efficiency
Overvoltage, rotating field sequence and temperature detection
IGBT technology
Self synchronizing

Summary
ATV71
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When do I need a Network Braking Unit ?
Advantages of the NBU compare to braking resistors
Energy saving
Volume saving
Efficiency
Quick response
Smooth DC bus voltage regulation

Disadvantages
The cost
Can't regen in case of network cut (no ride through operation)
Can increase a little the network voltage (supply impedance must be <6%)

Thus the NBU is justified:
When there are frequent and quite long cycles of regenerating (braking)
Where the place is a problem
Where heat dissipation is a problem
Where the units can be share by several drives

Ex : Hoist movement, high inertia machine

Summary
ATV71
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Offer
Main specifications

2 power ranges
380V- 415V 7kW to 200kW
440V-480V 18kW to 180kW
Frenquency : 40 - 60Hz +/-10%
Effiencency : 97%
Cos = 1
Line inductance (4% to 6% => THDI<48%)
DC bus protection (fuses + diode)

Working temperature :
5C40C without derating
55C with derating (3%/C)

CE : low voltage directive

IP20

Drive
NBU
Summary
ATV71
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Network Braking Units recommended diagrams
Line chokes built in
4%-6% THDI <=40%
DC bus fuses built in
For power >=45kW an
external 220V supply is
required for fans
Diodes anti current return
built in
ATV71 optional EMC filter
can be used
1 NO-NC relay
NBU ready
Ext On/off and reset
Summary
ATV71
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Offer
7,6
13.8
22
33
45
70
90
135
160
200
250
345
Ppeak
400V
380V-415V offer
from 7 to 200kW
continuous braking
power
3 . . min
ac line peak
Irms U P =
Summary
ATV71
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Offer
22
33
45
70
90
110
125
140
160
230
400
Ppeak
440V-480V offer up
to 240kW
continuous braking
power
Summary
ATV71
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Ex of NBU paying off calculation
Ex for a hoist application

Braking power P
b
= 100kW
Braking time per cycle t
b
= 10s
Number of cycles per hour n = 30/ h
Operation hours per day h = 18h / d
Working days d = 350d / y
Energy-costs K = 0,1 EUR / kWh
Costs of the power feedback unit R
K
= 6600 eur
Costs of equivalent braking resistor C
K
= 2800 eur

Energy saving per year

Energy-costs saving per year:

Paying off in days:

The network feedback unit is paid off within 9 months.

3600
350 18 30 10 100 y d d h h s kW
W
/ / /
=
year kWh W / 52500 =
K W E =
kWh e a kWh E / ur , / 1 0 52500 =
year e E / ur 5250 =
F K B n t P
C R
A
T B B
K K

=
) (
eur d h h s kW
s eur eur
A
1 0 18 30 10 100
3600 2800 6600
, / /
) (

= days 254 = A
Summary
ATV71
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I. The Offer

II. How it works ?


IV. Sizing example

V. Appendix

Summary
ATV71
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Network Braking Units internal structure
Internal diagram VW3A7211 (135kW)

Summary
ATV71
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Network Braking Units working
DC bus management

II The DC-bus voltage increases, when the motor is in regenerative mode. The feedback current increases
straight proportionally with the DC-bus voltage.

IV The difference between the generated and inverted voltage and the mains voltage is the necessary
voltage which drives the current back to the mains. Therefore the mains network operates as energy drain,
where a minimal voltage increase can be seen (depending on the network impedance at this point).

V Between 620 and 630V DC the IGBTs trip due to an overcurrent -> the NBU is locked till reset operation.
The time delay for overcurrent tripping is 10s.

460Vac

444Vac

400Vac

II

I

III

IV
V
620-630Vdc Ir = 120% Imax
NBU tripping Threshold
600Vdc Ir = 100% Imax
max peak power
540Vdc Ir = 0% Imax
750-850Vdc
Drive tripping Threshold
Example for a 400V NBU :
Summary
ATV71
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Main features
Set up
No settings, in factory configuration the NBU is ready to work
However :
Check the supply voltage is corresponding to the NBU name plate
Check the network connection L1,L2,L3 (the phase rotation must be respected)
Check the DC bus connection from the drive (+/-)
Check the fan supply connection (>45kW)
Check the fault relay is connected to external fault input of the drive

At voltage turn on the green led is lighten the NBUis ready to work

In case of fault there are other leds for trouble shooting

1. red: phase failure
2. red: overcurrent
orange: overtemperature

The reset button allows acquit the fault

Internal jumpers allow to set different ways of tripping and autostart in case of fault

Summary
ATV71
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I. The Offer

II. How it works ?


IV. Sizing example

V. Appendix

Summary
ATV71
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Sizing of the Network Braking Units
The basics

Sizing the Network Braking Units for the technical and economic optimum requires to
know several characteristics of the application.

Without this knowledge you choose the NBU in accordance with the continuous and
maximum power rating of the drive.

Naturally this will not lead to the best economic solution as most often the NBU will be
oversized.

The sizing can be done in 3 steps :
- 1. Calculate the electrical braking power to feedback
- 2. Calculate the NBU peak power (function of the minimum network voltage)
- 3. Choose the corresponding NBU power rating

Summary
ATV71
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Electrical braking power calculation
To size the Network Braking Units you must know :
the peak braking power Pb to feedback
the mean braking power Pb to feedback

Ex of a braking power cycle :

The power is depending on the cycle, the inertia, the load and the efficiency of the system.
Braking power
Pb2 Pb1
T
t0 t1 t2
Pb
Pb
T
t P t P t P
P
b b b
b
2 2 1 1 0 0
. . . + +
=
Summary
ATV71
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Real regenerating power

The braking power calculated results of the energy that is fed back from the mechanical
system.
Not the whole energy comes back to the Network Braking Units unit.
The mechanical friction, inverter losses help for braking.
These losses are generally represented by the efficiency (q) of the system.

In an other hand some loads can increase the braking power, as for example the wind
on a crane jib arm.

Anyway, it's good to take a safety margin.
For example, to simplify the calculation, efficiency (if not supposed very bad) can be
considered q = 1.
drive mot mec t
q q q q . . =
t mec b real b
P P q - =

Summary
ATV71
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Power flow during regenerating phase
L1
L2
L3
U
V
W
M
3 ~
Drive
Network Braking Unit
Network
M, w
J
L1
L2
L3
Input-
rectifier DC-bus-
capacitor
Inverter Motor
Load
Power
regenerated
onto the network
Motor
losses
Mechanical
losses
System
mechanical
Power
Motor elec.
power
Motor mec
power
Inverter
losses
Network
Braking
Units
losses
Braking
power
cos . . . 3
m m em
I U P = e . T P
mm
=
mec mot d mec b
P P q q q . . . =
dt
d
J P
mec
2
e
. =
dc dc dr
I U P . =
3 . .
min max n r
I U P =
>
Summary
ATV71
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Some efficiency datas*

Drive efficiency
0.37- 1.5kW 0,9-0,94
2.2kW-500kW 0,95-0,97

AC Motor efficiency (standard)
0.37-3kW = 0,75-0.82
4-7.5kW = 0,85
11-55kW =0.9-0.93
75-500kW =0,95

Transmission part efficiency
Gear box = 0.8-0.95
Pignon-Rack = 0.7-0.8
Belt or Chain = 0.95
Endless screw = 0.6-0.8
*Can be used for a first approach calculation

Summary
ATV71
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Effective regenerating power
With a Network Braking Units the power regenerated is depending on the network
voltage.
Thus the minimum network voltage must be considered in order to size the unit.
Ex :
for an application 32kW barking peak power is calculated
33kW 400V unit VW3A7204 is chosen
but the network voltage can decrease to Umin = 340V
max ac current for VW3A7204 => In = 48A

If we take into account the min voltage, the peak regenerating power available is only :

It would be better in this case to choose a range above VW3A7205 (45kW 400V)

kW P I U P
r n r
28 3 340 48 3 = = = . . . .
max min max
Summary
ATV71
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I. The Offer

II. How it works ?


IV. Sizing example

V. Appendix

Summary
ATV71
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Sizing of the Network Braking Units ex.1
Simplified example for a hoist application
Motor torque
t
Speed
Network = 400V +/-5%
Braking power reflected on the
motor shaft 160kW
Motor efficiency =0.9
Drive efficiency =0.98
Braking
Power
3s
3s
3s 30s 40s
T1=40s T2=3s T0 = 79s
1.8 Tn
0.8 Tn
0.8 Tn
1.8 Tn
up
down
kW P
b
5 45 88 0
3 40 79
3 160 8 1 5 0 40 160 8 0
. .
) . . ( ) . (
= -
+ +
- - - + - -
=
88 0 98 0 9 0 . . . = - =
t
q
t n b
P P q - - = 8 1.
t
b b b
b
T
t P t P t P
P q .
. . .
2 2 1 1 0 0
+ +
=
kW P
b
253 88 0 160 8 1 = - - = . .
Peak regenerative power :

Mean regenerative power :
Efficiency :
Summary
ATV71
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Choice of the braking unit

1- Choose a module witch maximum peak power
is equal or higher the peak braking power
calculated (230kW).
Ppeak power of the module VW3A7212:
Ppeak = Irms*Umain*SQR3 Ppeak
=500*380*SQR3 = 329kW > 253kW
2- Check that the continuous power is
equal or higher than the mean braking
power calculated (45.5kW).
P mean = 200kW >45.5kW
Or check with the duty cycle
Summary
ATV71
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Exemple of using the catalogue diagram for a cycle
Example 1 :
necessary braking power : 33 kW
braking duration : 2 min.
time between two brakes : 5 min.
Evaluation: In this case the point of
intersection of braking time and
intermission time is below
the thermal limited power graph in the
allowed area this operation cycle is
allowed.

Example 2 :
necessary braking power : 45 kW
braking duration : 3 min.
time between two brakes : 3 min.
Evaluation: In this case the point of
intersection of braking time and
intermission time is above
the thermal limited power graph.
That means this operation cycle is not
allowed.
Remark: In case of an intermission time
of e.g. 3,5 min. this operation cycle
would be allowed again
Summary
ATV71
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I. The Offer

II. How it works ?


IV. Sizing example

V. Appendix

Summary
ATV71
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Example of association of several modules
2x Regen
modules
110kW
VW3A7210
ATV71
90kW
ATV71
90kW
ATV71
110kW
ATV71
45kW
Regen
module
26kW
VW3A7205
Up to 4 modules // possible, the
range can be different.
Summary
ATV71
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Calculation of mechanical braking power
Braking power for an horizontal movement (ex trolley)
constant deceleration (n->0) and negligible inertia and friction
Braking power
Pb
tb
Pb
Speed
Torque
b b
P P .
2 =
b
kin
b
t
E
P =
2
2
1
v m E
kin
. .
i n r v . . . t =
E
kin
(j) = kinetic energy
m (kg) = mass of the mobile
v (m/s) = linear speed
r (m) = radius of the wheel
n (t/s) = motor speed
i = gearbox ratio
t
b
(s) = time to stop
P
b
(W) = mean braking power during stopping
P
b
(W) = peak braking power during stopping
n
Summary
ATV71
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Braking power for an inertia (ex flywheel)
constant deceleration (n->0) and negligible friction
Braking power
Pb
tb
Pb
Speed
Torque
n T b P
b
. . .
t 2 =
b
tm b
t
n
J
dt
d
J T
.
. .
t e 2
= =
2
i
J
J J
wh
mot tm
+ =
T
b
(N.m) = braking torque
J
tm
(kg.m
2
) = total inertia reflected to the motor
J
mot
(kg.m
2
) = inertia of the motor
J
wh
(kg.m
2
) = inertia of the wheel
i = gear box ratio
(kg/m
3
) = wheel material density
v (m
3
) = wheel volume
s (m
2
) = wheel surface
t
b
(s) = time to stop
P
b
P
b
s v J
wh
. . =
Tb
2
b
b
P
P

=
M
i
J
mot

J
wh

n
b
tm b
t
n
J
dt
d
J T
.
. .
t e 2
= =
b
tm b
t
n
J
dt
d
J T
.
. .
t e 2
= =
b
tm b
t
n
J
dt
d
J T
.
. .
t e 2
= =
Summary
ATV71
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Braking power for constant speed (ex motor test bench)
negligible acc/dec power, inertia and friction
Braking power
Pb
tb
Speed
n T P P
b b b
. . .
t 2 = =
T
b
(N.m) = braking torque
g (m/s
2
) = gravity acceleration
m (kg) = mass of the mobile
P
b
P
b
M
n
G
Torque
Tb
v g m P P
b b
. .
= =
Summary
ATV71
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Calculation formulas of the braking power for a vertical movement
T (s) = total cycle time
t
0
(s) = stop time + ascent time t
1

(s) = descent time t
2

(s) = stop time in descent
P
b1
(W) = mean braking power during descent
P
b2
(W) = mean braking power to stop in descent
P
b2
(W) = peak braking power to stop in descent
e
m
(rd/s) = max angular speed
J
tm
(kg.m
2
) = total inertia reflected to the motor
g (m/s
2
) = gravity acceleration (9,81)
a (m/s) = load deceleration
T
t P t P
P
b b
b
2 2 1 1
. . +
=
Braking power
Pb2 Pb1
Pb
T
t0 t1 t2
Pb2
Braking Torque
Speed
v g m P P
b b
. .
= =
1 1
Up
down
1
2
2
t
J v a g m P
b
e
. ). .(
+ + =
2
2
2
b
b
P
P

=

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