PQIG 2009 - Electric Power Research Institute
Contents
1. N ie e gt 42 Example Control Level Solutions at the Distribution Panel and Recommendations Sometimes the most effective pd solution 15 to provide MCC Bus conditioned power for the entire IPP Panel Advantages of this 480Vac 3 Phase from 50 approach include po Simplified Cut Over Fewer i m Touch Points 208Vac s Phase Single Power Conditioner for many loads eet When sized to support kVA of transformer this approach will Support future expansion panels IPP PC 43 Copyright 2009 Electric Power Research Institute Inc All rights P QI G 2 0092. he dynamic torque profile was nns test to follow the High Torque Parameter the default slip Input Phase Loss Ignore compensation was set to 100 Catch on Fly Yes UV Timeout 3 sec UV Prevention DC maintain Slip Compensation 100 default Dynamic Torque High Torque A 23 Copyright 2009 Electric Power Research Institute Inc rights res P QI G 2 009 Method 5 Select Appropriate Trip Curves for Circuit Breakers Load Current During 12 Cycle Sag 200 h REA 4 h e SCA Ar OO 0 05 0 15 0 2 Time seconds Load Current amps c c al ligi 28 100 4 10 Figure 2 Load Current During Sag Trip Time in Seconds Load Current During Sag 150 160 Amps 100 200 300 400 500 600 700 800 900 1 000 1 100 1 200 New Breaker Percent of Rated Current 100 5 EMEN T 2 50 M Sy ene MAA MMMM AMT aMn DON WWNWNWENWKV UM Time seconds Figure 4 Response of New Circuit Breaker 24 Copyright 2009 Electric Power Research Institute Inc All rights rese PQIG 2009 Other Considerations Make sure the device rated voltage matches the nominal voltage Mismatches can lead to higher voltage sag sensitivities for example 208Vac
3. writ ng variables to non volati le 3 IF PE COUNT EQUALS THREE AND 1 15 STOPPED MOVE 5011 151 AND memory in the event power 15 INCREMENT PUSH Coun t 4 IF PUSH COUNT EQUALS 1 AND 011 IS HOME TURN 1 OSI 5 IF PE COUNT IS EQUAL TO 6 AND M1 IS STOPPED MOVE 5011 TO 152 AND INCREMENT PUSH_COUNT When power retu rns the 6 IF PUSH_COUNT EQUALS 2 AND SOL1 IS HOME MOVE SOL2 TO LS3 AND INCREMENT PUSH_COUNT processl step nu mber and 7 IF PUSH COUNT EQUALS 3 AND 5012 IS HOME EXTEND SOLENOID 2 FOR 5 variables be recalled so that 8 IF 50L3 TIMER I DONE TURN 2 FOR 5 SECONDS AND RESET ALL COUNTERS the machine continue from AND TIMERS PE COLUNT AND PUSH COUNT where it stopped 12 Copyright 2009 Electric Power Research Institute Inc 2 009 13 Method 3 Apply Custom Programming Techniques Programming Using Phase Voltage Sensing Relay A phase monitor or voltage sensing relay used conjunction with programming can also protect against the effects of voltage says The relay contacts be used to run a check on the system retrieve past information stored in memory or hold control parameters constant until the event 1s over Copyright O 2009 Electric Power Research Institute Inc All rights res Potential Sensing Devices For Voltage Sags Left to Right Phase Monitoring Relay PQ Relay Original PQ Relay AC Ic
4. Duration of Sag What other benefits does DC have What are some design considerations with DC Process Control Signals DC Powered PLC Circuit Copyright 2009 Electric Power Research Institute Inc All rights 1 P QI G 2 009 DC Powered PLC System Weld Shop ax adi 3 Three phase input Siemens SITOP DC Power ie supplies rl 3 SLC 5ix SERIE aeree IET PLC with DE va E mE 1 ital He aT om mm uil ia ait dl Magnitude Parcan taga cT Pra Nag Chretien yelni A p SLC PLC Copyright 2009 Electric Power Research Institute Inc All rights reserved PQIG 2009 Summary of Robust Power Supply Strategies Relative Power Supply Response at 100 Loading Type of Power Supply Sag Tolerance Curve Ride Through for Switch Mode DC Single Phase Voltage Power Supply d i Sags 480 208 VAC 3 Phase Switch Mode DC Power Supply Universal Input Switch Mode DC Power Supply Connected Phase to Phase Copyright 2009 Electric Power Research Institute Inc All rights reserved PQIG 2009 Method No 2 Utilize Sag Tolerant Components IF AC Relays and Contactors are used in the semiconductor tool design then utilize compliant Tepe his eure devices e Consider response at both 50 and 60 Hz We have certi
5. 2 ir e er a 5 5 cw e gt 5 LO n gt gt Os Example Response Example Worst Case Speed Deviation 12 im rd SU 2 9 5 2 QJ oN gt Of wO 0 x OAL 0 sat 0 22 Schneider Toshiba 61 amp 71 Drives This newer drive series was recently tested as a part of the EPHI PQ Star SEMI F47 compliance program Drives were found to pass the Standard Certification Relates to multiple drive models manufactured from same control platform SII Altivar 61 and 71 ELIN gt pDRIVE lt MX ECO and MX PRO Altivar 61 and 71 Series Drives Copyright 2009 Electric Power Research Institute Inc All rights reserve P QI G 2 009 Schneider Toshiba 61 amp 71 Drives The drives were able to pass the SEMI F47 testing requirements i RUND when configured properly M Prameters such as Input 800 RPA 7 7 1 T1 T1 T T Phase Loss Catch on the Fly and Undervoltage UV Timeout had to be set
6. fed to 230Vac rated component Consider Subsystem performance Vendor subsystems must be robust for the entire system to be robust Otherwise power conditioning may be required for the subsystem Consolidate Control Power Sources This will make the implementation of any required power conditioner scheme much simpler and cost effective Usea targeted voltage conditioning approach as the last resort Apply Batteryless power conditioner devices where possible next 25 Copyright 2009 Electric Power Research Institute Inc A fi P QI G 2 009 On Control Pewer Transfarrmer Machine On CONI Use of Selective Power Conditioners Continuous ELECTRIC POWER 26 RESEARCH INSTITUTE C Se ENERGY Selective Conditioning The Premise All equipment power users are not ultra sensitive The Plan To prop up the single phase weak links only The Weak Links small single phase 100Vac 230Vac typically power supplies sensors and controls The Benefit Lower Cost than Macro Solutions 27 Copyright 2009 Electric Power Research Institute Inc All rights reserve P QI G 2 009 Uninterruptible Power Supply UPS For Control Loads A 1 Small 500Va to ES i T 3kVA E Charger UPS Systems are M sometimes Used Regulating Transformer 77 Battery Inverter Battery Based saten UPS _Rectereharge
7. power and work aS To Motor Starter To Motor Starter a mechanism for when components drop out due Start Push Stop Push to a voltage sag The PLC motor control circuit shown demonstrates how this method can be applied MS Coil Contact program is designed to detect whether the auxiliary contact is open for more than Co 007 Motor Starter TIMER ON DELAY 250 milliseconds Rung 2 Time Bass 00 Timer On MS Coil Rung 1 Preset Value 25 e If the contact is open for more secret Vaus S than that preset time then the Timer On Delay Coil in Rung 2 will set and unlatch the previous rung to remove voltage from the motor starter 11 Copyright 2009 Electric Power Research Institute Inc All ric 2 009 Method 3 Apply Custom Programming Techniques State Machine Programming Solenoid 3 Welding Bar State Machine Programming is As ded based on the idea that P manufacturing processes are First Push 3 comprised number of steps with the goal of producing and moving a product e Therefore machine state programming keeps track of every seq u ntial process State programming uses coding such as shown below to store and retrieve data and associated variables by 1 IF PE COUNT AND PUSH COUNT EQUAL 0 THEN TURN 1 ON Ts _ 2 WHEN COUNT PE COUNT EQUALS 3 STOP CONVEYOR
8. Cost less than 150 250 USD per unit Suppliers www pqsi com UL Certified www scrcontrols com 37 Copyright 2009 Electric Power Research Institute Inc All rights rese Calvert City PA Mon SEMI F47 Carbide PQ Mon 100 90 D Vnominal Coil Hold In Device keeps Relay Motor Starter or 20 30 40 Cycles PQS Contactor Input VAC COIL LOCK Coil Figure 2 PQIG 2009 38 Machine and Panel Level Solutions Process Equipment or Line 3 Process Process Equipment or Equipment or Line Line 2 One Piece of Equipment or One Line Protected ELECTRIC POWER RESEARCH INSTITUTE ENERGY Cost of Solutions Versus Knowledge of Sensitivity Utility Solutions Whole Im Solution Protect Entire Facility PAM 10 T get Panel Feeder Solution c Protect Feeder or Group of Machines 105 Machine Solutions 104 Protect Whole Machine or Machine Control Circuits Relative Cost of Solution 10 Control Level Solutions Power Conditioners 10 More Robust Relays Power Supplies Contactors Sensors etc Knowledge of Equipment Sensitivity 39 Copyright 2009 Electric Power Research Institute Inc All rights rese P QI G 2 009 Pro DySC he ProDySC provides equipment and process level protection without the use of batteri
9. Voltage Sag Mitigation Methods 10 28 09 1 15 pm 2 00 pm Mark Stephens PE senior Project Manager Industrial Studies Electric Power Research Institute 942 Corridor Park Blvd Knoxville Tennessee 37932 Phone 865 218 8022 mstephens epri com 5 ELECTRIC POWER RESEARCH INSTITUTE Cost of Solutions Versus Knowledge of Sensitivity 10 105 104 Relative Cost of Solution 103 102 FS a Utility Solutions Whole Plant Solution Protect Entire Facility EN E Panel Feeder Soluti ane eeder lt Feeder or L Group of Machines Machine Solutions 2rote Machine Machine Control Circuits og Control Level Solutions Power Conditioners More Robust Relays Power Supplies Contactors Sensors etc Knowledge of Equipment Sensitivity Copyright 2009 Electric Power Research Institute Inc All rights rese P QI G 2 009 Example Solution Levels Control Level Control Level Machine or Subsystem Level Power Conditioning Embedded DC Solution 1 10 to 1 20 of Machine Level Power Conditioner Cost Best done by OEM in design phase Power Conditioning On Control Pewer Transfarrmer Power Conditioner Machine On COMI Conditioner Process Process Process Equipment or Equipment or Equipmen
10. e Cube PQIG 2009 Method 4 Examine Configuration Settings A low cost or perhaps no cost method of increasing the tolerance of AC and DC motor drives to voltage sags is through software configuration settings This method applies to all types of drives including but not limited to AC pulse width modulation PWM direct current AC pulse stepper and servo drives 14 Copyright 2009 Electric Power Research Institute Inc All ric 2 009 In most cases drive manufacturers give users access to basic microprocessor program parameters so that the drive can be configured to work in the user s particular application drive s programming parameters associated with reducing the effect of voltage sags are seldom describes in one section of the user manual 15 Copyright 2009 Electric Power Research Institute Inc All rights t Method 4 Examine Configuration Settings Functional Description Automatic Reset and Automatic Restart Parameter Automatic Reset Automatic Restart Automatic Restart Attempts Automatic Restart Interval Automatic Restart Time Delay Restart at User Defined Frequency Setting Flying Restart Parameter Description This parameter allows the drive to automatically reset some fault conditions such as DC link undervoltage or overvoltage without the need for operator user intervention This feature is used in conjunction
11. es or fly wheels The unit can boost incoming line voltage and provide momentary ride through protection for sags down to zero volts It is designed to handle short term sags up to two seconds with a 30 second recharge time This unit is three phase 200 480 volts 25 200 amps and supports between 333 and 2000 Copyright 2009 Electric Power Research Institute Inc All ric PQIG 2009 Omniverter he Active Voltage Conditioner AVC consists of an inverter which feed an injection transformer in series with the utility The inverter allows the unit to correct utility disturbances oince there are no storage devices no maintenance 15 required comes in a three phase 208 480 and 600 volts but has 400 and 690 volt options It has a very fast response time of in less than a millisecond because It 1 continuously running It can also protect against rapid consecutive sags 41 Copyright 2009 Electric Power Research Institute Inc All rights res PQIG 2009 TB4 Qutput to Load DySC to Load 2 Line to DySC TB1 Line Input Purchase Bypass with uni PQIG 2009 liz T T Ti Cr Cr X 0 5 o pum lt pus ip A
12. fied a many relays and contactors to SEMI F47 On EMO Emergency Button Off Button Relay Step Down Transformer EMO Relay Relay Main Contact 2 Contact 1 Contactor Contactor Telemecanique LC1F150 Coil LX9FF220 Voltage Sag Ride Through Curve DUT 60HZ SEMI F47 50HZ To Tool Subsystems and Other EMO Circuits Voltage of Nominal 0 0 1 02 03 04 05 06 07 08 09 1 Duration seconds Copyright 2009 Electric Power Research Institute Inc rights re P 2 009 Example Voltage Sag Response of Motor Controls Based on Robustness of Components From Separate 120 V Source Machine On E Stop CR cb codice erii neus z 2 Interlock or Rem Stop Start PLC Circuits with Non Compliant Components i 0 0 5 1 Total Tolerance of Motor Control Circuit without Compliant Components Circuits with SEMI F 47 Compliant Components 0 0 5 1 0 0 5 1 0 05 1 Motor Starter Total Tolerance of Motor Control Circuit with SEMI F 47 Standard Curve Compliant Components 10 Copyright 2009 Electric Power Research Institute Inc All rights reserve QI G 2 009 Method 3 Apply Custom Programming Techniques Delay Filters e Delay filters can be verify the presence of
13. r UPS Are Often IL Overkill Battery Battery Charger String Abandoned in Place UPS Systems 28 Copyright 2009 Electric Power Research Institute Inc All rights reserved P QI G 2 009 Square Wave Compatibility with PLCs DPI oquare Wave Output UPS PLC Model Compatible Outcome with Outcome with with 120Vac APC Smart UPS 420 APC Back UPS Pro 650 Input Cards Omron PLC A Toggling input could not Toggling input could not be resolved be resolved TI 545 PLC B inputs dropped inputs dropped leading to the logical leading to the logical decision to drop the decision to drop the control relay control relay Quantum PLC C Same as TI 545 Same as TI 545 AB PLC 5 PLC D No Effect System OK No Effect System OK AB SLC 5 05 PLC E No Effect System OK No Effect System OK 9 29 Copyright 2009 Electric Power Research Institute Inc All rights reserved P QI G 2 009 UPS Coverage vs sample Historical Data PO Events F 47 0200 d 0 00 0 05 0 10 0 15 0 20 0 25 0 30 0 35 0 31 0 98 0 50 0 55 0 80 0 65 0 70 0 75 0 80 0 55 0 90 0 55 1 00 D uration Seconds PQIG 2009 30 Copyright 2009 Electric Power Research Institute Inc All rights MiniDYSC he Dynamic Sag Corrector from Softswitching Technologies Deep Sag Coverage especially when lightly Loaded Has Capacitors tha
14. rs or batteries Accurate i control adjustable Ey through time amp variable transfer evel Primarily designed for inductive and low power factor loads 120Vac and 208Vac Models Square Wave Output www measurelogic com www dipproof com Copyright 2009 Electric Power Research Institute Inc All rights res un 0 00 0 05 0 10 0 15 0 20 0 25 0 30 0 35 0 40 0 45 0 50 0 55 0 80 0 65 070 0 75 0 80 0 85 0 90 0 95 1 00 Duration Seconds Motor Control Centre By Pas 5 Switch 2 Contro Voltage A typical connection diagram PQIG 2009 34 PowerRide RTD Uses two phases of three ohase supply as input and a single phase output If one phase in interrupted constant power out of the RTD Even if the remaining phase drops by a third Typically No Need to oversize for Inrush htt WWW U I ups com Vnominal 7 Single Phase to i Process RID Controls WYE Connection Copyright 2009 Electric Power Research Institute Inc All rights DELTA Connection PQIG 2009 Constant Voltage Transformer CVT On line Device In Rush Current of load s MUST be considered In sizing Output of CVT can collapse when in rush current gets close too high around 4 x rated size Sub Cycle Response Should be oversized to at lea
15. search algorithm to determine the motor speed Once the speed is recognized the drive reaccelerates the motor to the desired operating point The odds of the motor and load experiencing extreme current and torque transients are greatly reduced PQIG 2009 Functional Description Motor Load Control Parameter Kinetic Buffering Motor Voltage Compensation Controlled Deceleration and Acceleration Parameter Description When the drive senses a DC link low voltage condition the drive uses the combined motor load inertial energy to maintain a factory programmed DC link voltage inside the drive by applying a braking force to the motor This feature does not create a potential for extreme current or torque transients When the drive senses a DC link low voltage condition the drive s controller changes the inverter firing timing sequences to compensate for a reduced DC link voltage The objective is to maintain as close as possible the desired output voltage for operating the motor and load When the drive senses a DC link undervoltage condition the drive begins to decelerate the motor at a user defined rate When the undervoltage condition ends the drive reaccelerates the motor back to the desired operating point This feature is often used in processes with multiple drives operating in succession where all drives are expected to operate in unison to maintain process quality This feature works well for common DC bus drive sys
16. st 2 times nominal of load to increase ride through Acts as an Isolation transformer and protects against voltage Sags 35 Copyright 2009 Electric Power Research Institute Inc All rights 1 9v nominal Calvert City Mon SEMIF47 Carbide PQ Protection if Sized Correctl Cycles O Primary Primary Section 2 gt Winding of the Core Magnetic Shunt P al Secondary Air Gap Winding Secondary Section Resonant gt Capacitor of the Core P Resonating Winding PQIG 2009 Example Application Source Power Disconnect 480 V Three Phase Three Wire ELB1 AC control components means that the selected power conditioner will be more affordable than one that could protect the entire machine Three Phase Disconnects he ride though of the AC drives in this example can be enhanced by modifying their programming thus eliminating the need for a large power conditioner PLC Power Supply PLC I O Control Circuit Protected Components Control Level Unprotected Components 36 Copyright 2009 Electric Power Research Institute Inc All righi P QI G 2 009 Coil Hold In Devices Will prop up relay or contactor coil down to 25 of nominal voltage sag e Customer will need to final Size the coil hold in device based on Voltage and Coil Resistance measure with an ohm meter
17. t allow for some ride through for interruptions Would handle all sags seen by equipment during monitoring period http www softswitch com Copyright 2009 Electric Power Research Institute Inc All righ 31 ov nominal e Calvert City P Mon SEMI F47 Carbide PQ 60 standard Coverage NE ERE 2 nd di 50 of Hom 50 BA Cycles PQIG 2009 No batteries no maintenance Fast compensation e Able to withstand high inrush currents omall footprint easy to retrofit oupport exceeds SEMI F47 standard requirements 120Vac and 208Vac Models e www measurelogic com www dipproof com 32 Copyright 2009 Electric Power Research Institute Inc All rights rese Voltage Dip Compensator VDC 9v nominal Calvert City Mon SEMI F47 N Carbide PQ Mon Standard Coverage econds 50 of nominal AT mode ee 80 sor 60 50 100 90 econds Jf nominal mode 30 Cycles Compensation Transformer Fig 1 Compensator Block Diagram PQIG 2009 Dip Proof Inverters DPI No batteries therefore no replacement and maintenance costs or hazardous waste Fast lt 700uS transfer off line system develops little heat amp fails to safety Able to withstand high inrush currents to oversize as with UPS s amp S Lightweight small amp easy to retrofit no step up transforme
18. t or Line Line 2 Line 3 One Piece of Equipment or One Line Protected Process Control Signals Copyright 2009 Electric Power Research Institute Inc All rights res P QI G 2 009 Designing bedded Machine On Solutions CONI B rd Process Control Signals ELECTRIC POWER EPE cps ENERGY One of the best methods of increasing the tolerance of control Voltage to Tool circuits is to use direct current DC instead of alternating current AC to power control circuits controllers input output devices and Sensors DC power supplies have a built in tolerance to voltage sags due to their ripple correction capacitors whereas control power transformers CPTs Method 1 Design with DC Power Main AC Box On E Universal Input DC Power Supply E Off Button Relay EMO Relay Relay Main Contact Contacti Contactor Main Contactor Contacts To Tool Subsystems and and AC components do not have Other Circuits inherent energy storage to help them ride through voltage sags DC Powered Emergency Off Circuit Many OEMs are moving in this direction to harden their equipment designs 5 Copyright 2009 Electric Power Research Institute Inc Al 2 009 PLC Using DC Power Supply Scheme How Much Better is the DC solution Depth of Sag
19. tage exceeds the delay time the drive faults Otherwise the drive continues normal operation Detecting a loss of phase enables a drive to delay a fault condition and ride through the loss of phase The DC link undervoltage trip point can be adjusted to enable a drive to ride through sags Copyright 2009 Electric Power Research Institute Inc All rights 2 009 Example Settings Rockwell Power Flex 70 4 700 Conducted SEMI F47 compliance Testing on Power Flex 70 and 700 Series drives in EPHI Lab Drives have built in parameters that can be used to Improve voltage sag performance Drives loaded to 10096 Copyright 2009 Electric Power Research Institute Inc All rights rese P QI G 2 009 Typical Drive Test Setup Dynamometer Control System Test Setup for Larger Drives 20 to 150HP Voltage Sag Generator Nicolet Data Recorder Eddy y Current Dynamic Heli F Drive Under gs AC os 1 Test otor 5 Test Setup for Smaller Drives 2 to 15 HP Nicolet Data Recorder fie Voltage Sag 15 HN Generator T d M 2 7 19 Copyright O 2009 Electric Power Research Institute Inc All rights reserved PQIG 2009 3 ____
20. tems Motor load control uses the motor s inertia or controlled acceleration deceleration to ride through voltage sags Copyright 2009 Electric Power Research Institute Inc All rights t Method 4 Examine Configuration Settings PQIG 2009 Method 4 Examine Configuration Settings Functional Description Phase Loss and DC Link Undervoltage Parameter Input Phase Loss Input Phase Loss Delay DC Bus Undervoltage Limit or Undervoltage Detection Level DC Bus Undervoltage Delay Parameter Description The input phase loss detection circuit monitors either the input phases or DC bus current ripple and activates when one of the input phases is lost In some drives an input phase loss alarm will be generated if the duration of the phase loss is greater than the input Phase Loss Delay setting This parameter controls the delay time in which an input phase loss must be present before a fault is generated If the input phase returns to nominal before the delay time a fault will not be generated Some drive manufacturers allow users to change the DC bus undervoltage trip point By lowering the trip point drives and processes may ride through longer and deeper voltage sags without interrupting production This feature may be standard or may require a drive software upgrade from the manufacturer This parameter allows the user to set a time delay for a DC bus undervoltage fault If the duration of the undervol
21. with Automatic Restart This parameter defines the method in which the drive automatically restarts after a fault condition is over Automatic Restart operations may only be used as outlined in NFPA 79 Equipment damage and or personal injury may result if the Automatic Restart parameter is used in an inappropriate application This parameter allows the user to program the number of times that the drive attempts to restart the motor after an undervoltage or other fault condition This parameter is a user specified time delay between the automatic restart attempts and the end of the fault condition This parameter is a user specified time delay between the end of the fault condition and an automatic restart When the drive senses a DC link undervoltage condition the drive shuts down the inverter allowing the motor to coast The motor is allowed to coast until the undervoltage condition ends The drive then restarts the motor at a user defined frequency setting If the restart frequency is significantly higher or lower than the frequency of the motor large inrush currents torque and speed transients could be induced on the motor and load The restart frequency setting the acceleration rate deceleration rate current limit and torque limit should be considered when using this feature This parameter is similar to the parameter above with one major exception Rather than restarting at a pre defined frequency setting the drive uses a
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