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Technical Guide
ON
MMUTATI
Medium
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Public measu on
Point of ucted emissi
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Point of emission
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)
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e gen or
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Se m M
III A 1-1
3ADW000163R0201_Technical guide_e_b
General
Contents
2 Technical environment
2.1 EMC Compliant Installation and Configuration
for a Power Drive System ....................... III A 2 -1
2.1.1 Introduction ............................................................... III A 2-1
2.1.2 Definitions ................................................................. III A 2-2
2.1.3 EMC Compliant Installation Guidelines .................... III A 2-4
2.1.4 Summary ................................................................ III A 2-14
3 Engineering of DC drives
3.1 Fusing aspects of DC drives .................. III A 3-1
3.1.1 General ..................................................................... III A 3-1
3.1.2 Armature supply ....................................................... III A 3-2
3.1.3 Field supply .............................................................. III A 3-4
3.2 Commutation ........................................... III A 3-5
3.3 Harmonics ................................................ III A 3-5
3.3.1 12-Pulse ................................................................... III A 3-1
3.4 Reactive power ........................................ III A 3-5
III A 1-2
3ADW000163R0201_Technical guide_e_b
1 General General
III A 1-3
3ADW000163R0201_Technical guide_e_b
General
III A 1-4
3ADW000163R0201_Technical guide_e_b
2 Technical environment Technical environment
2.1.1 Introduction
General Practical Installations and Systems
This guide assists the design and installation This manual gives a brief insight of EMC in terms
personnel when intending to achieve compli- of definitions and offers practical EMC solutions
ance with the requirements of EMC Directive in and a connection example with essential re-
the users systems and installations, when using marks and hints for the EMC compliance of
DCS converters. power drive systems. The solutions can be di-
rectly used or applied by OEM or Panel builder.
The purpose of this chapter
The purpose of this chapter is to guide Original The Directives concerning Drives
Equipment Manufacturers (OEM), System Inte- There are three directives that concern variable
grators and Panel builders in designing and speed drives. They are Machinery Directive,
installing DCS converters and their auxiliary Low Voltage Directive and EMC Directive. The
components into their own installation and sys- main objective of the EMC Directive is to guar-
tems. The auxiliaries include EMC filters, line antee the free movement of apparatus and to
reactors, fuses, etc. If these instructions are create an acceptable electromagnetic environ-
followed, it is possible to fulfil EMC requirements ment in the European Economic Area (EEA).
and give CE marking when necessary.
Product-specific Manuals
Definitions The detailed information of the installation and
The EMC Product Standard for Power Drive use of products can be found in product-specific
Systems, EN 61800-3 (or IEC 1800-3) is used manuals included in the product package. This
as normative standard for variable speed drives. guide is meant to be used together with product-
The terms and definitions applied in the stand- specific manuals.
ard are also used in this manual. The different
types of equipment used in this guide (refer to
section 2.1.2 Definitions) are the same as de-
fined in the EMC Directive.
III A 2-1
3ADW000163R0201_Technical guide_e_b
Technical environment
III A 2-2
3ADW000163R0201_Technical guide_e_b
Technical environment
Apparatus
A finished product containing electrical and/or Public low-voltage network Industrial low-voltage network
electronic components and intended to be placed Point of measurement
for conducted emission Point of measurement
on the market and/or taken into service as a
1 st
Environment 2 nd Environment
single commercial unit.
System
Several items of apparatus combined to fulfil a
specific objective and intended to be placed on
the market as a single functional unit.
10 m
III A 2-3
3ADW000163R0201_Technical guide_e_b
Technical environment
III A 2-4
3ADW000163R0201_Technical guide_e_b
Technical environment
III A 2-5
3ADW000163R0201_Technical guide_e_b
Technical environment
1 Classification
First environment (residential area with light industry) with restricted distribution
satisfied
Residential area Supply transformer for a residential Light industry Supply transformer for a residential
area (rating normally 1,2 MVA) area (rating normally 1.2 MVA)
Residential area
19 Earthed 19
neutral
Earthed
neutral Earthed public 400-V Earthed public 400-V Earthed public 400-V
network with neutral network with neutral network with neutral
conductor 18 conductor 18 conductor 18
21 21 21 21 21 21 21 21 21 21 21
9 / 24 9 / 24 9 / 24 9 / 24 9 / 24 9 / 24
2 2 2
To other loads which have to be protected from the system disturbances caused by
power converters (HF interference and commutation notches)
To other loads which have to be protected from the system disturbances caused by
5 5
22 23 22 23 22 23 22 23 22
4 4
4
Line reactor +
Line reactor Y-capacitor Line reactor Line reactor
alternative
25 25 26 25 26 25 25 25
13 13 14 13 14 13 13 13
M M M M M M M M
Operation at public An isolating transformer Operation at public Operation at public An isolating transformer
low-voltage network with an earthed screen low-voltage network low-voltage network with an earthed screen
together with other and earthed iron core together with other together with other and earthed iron core
loads of all kinds. renders mains filter and loads of all kinds. loads of all kinds. renders mains filter and
line reactor superfluous. line reactor superfluous.
III A 2-6
3ADW000163R0201_Technical guide_e_b
Technical environment
Standards
EN 61000-6-2
satisfied
EN 61000-6-1
Medium-voltage network Medium-voltage network
21 21 21 21 21
9 / 24 9 / 24 9 / 24
2
To other loads, e.g. drive systems
Mains filter
22 23 22 23 22 23
4 4
Line reactor +
Y-capacitor Line reactor Line reactor
alternative
alternative
alternative
26 25 26 25 26 25 26 25
III A 2-7
3ADW000163R0201_Technical guide_e_b
Technical environment
L1
L2 3-PH FILTER For vSC = 4 %: XPCC 5.40 m (LPCC 17.2 H)
L3 M For vSC = 6 %: XPCC 8.12 m (LPCC 25.8 H)
PCC
Notches 20 %
1-PH FILTER Example:
N
XPCC
20%
XPCC + XCHOKE
Fig. 2.1/6 Connection of single and three phase filters For vSC = 4 %: XCHOKE 4 x XPCC = 21.6 m
(LCHOKE 68.8 H) XCHOKE 4 * XPCC
For vSC = 6 %: XCHOKE 4 x XPCC = 32.48 m
Line choke
(LCHOKE 103.2 H)
4 Line reactors (Commutation reactors)
Converters cause short-duration short circuits
at their AC inputs, so - called commutation For vSC = 4 %: IDC 633 A
For vSC = 6 %: IDC 422 A
notches. Such notches down to 0 V (100% Converter
depth) can be accepted at the secondary wind-
ings of converter (dedicated) transformers (op-
eration without line reactors). However, their Fig. 2.1/7 Required minimum line reactor
impedance for installation of converter in first environment
depth must be reduced if the same transformer
shall supply more than one converter. In such
Often the maximum current is not limited by the
case line reactors are necessary. They must
transformer but by the power cable to the indus-
cause about 1% relative voltage drop at rated
try region. Therefore it is necessary to ask the
current. So - called 1% reactors are also neces-
energy supply company concerning the line
sary if the power of the converter is very low
impedance and the current which is available at
compared with the available power of the trans-
the desired point of common coupling (PCC).
former or supply line. ABB offers suitable 1%
III A 2-8
3ADW000163R0201_Technical guide_e_b
Technical environment
7 Installation hints
8 Cabinets
All metal cubicles available on the market can be
used; however, their mounting plates must have
well conducting surfaces according to 9 . If a
drive system is placed in more than one cubicle
their mounting plates must be connected by
broad pieces of well conducting sheet metal.
9 Mounting plate
The mounting plate must be made from steel
with zinc surfaces and without any painting. The
Fig. 2.1/8 Connection of a cable screen with the aid
PE copper bar must be mounted directly on the
of metal clamp to the metal surface of the PCB carrier at a
mounting plate without any insulating means DCS converter
between, and it must be connected with the
plate by several bolts distributed in equal dis-
13 Power cables with screens
tances along its length.
Power cables with screens are necessary, if
they run over long distances (>20 m) where they
10 Placement of devices are susceptible to EMC environmental condi-
The converter, the line reactor, fuses, contac- tions. The cable may have e.g. either a braided
tors and the EMC filter are to be placed on the or spiral screen made preferably of copper or
mounting plate so that the connections can be aluminium. The transfer impedance ZT of the
III A 2-9
3ADW000163R0201_Technical guide_e_b
Technical environment
power cable must be less than 0.1 /m in the with them on a cable rail as shown in principle by
frequency range up to 100 MHz, in order to the fig. 2.1/10 with n=4.
ensure an effective reduction of emission and a
significant increase of immunity. The screen PE + - PE + - PE + - PE + - PE
must be pressed by a well conducting metal
clamp directly against the mounting plate or the Armature Field Cable rail is effective
PE current current as shield against
PE bar of the converter cubicle (see 24 ). Another protective cables cables RF radiation
conductors (to be grounded at both ends
connection option is via EMC sleeve. according to 24 )
III A 2-10
3ADW000163R0201_Technical guide_e_b
Technical environment
conductor must be earthed (local earth of the on the same line caused by commutation notch-
house or plant), and then it is split into a neutral es can be solved with the aid of line reactors (see
and a PE conductor. Therefore a 3-phase load 4 ).
with neutral conductor must be supplied by a 5-
wire cable. Converters, however, are 3-phase Insulated lines must have also an earth conduc-
loads which do not need the neutral conductor in tor. The earth conductor is important for the
most cases. They can be supplied by 4-wire feedback of parasitic RF noise currents from the
cables as shown in fig. 2.1/5. The change from DC motor via the converter to the earth point of
the earthed neutral conductor outside the house, the supply transformer of the line. Without such
plant or factory to the internal PE conductor with a conducted feedback the loop of the parasitic
the local earthing point between is not shown in RF noise current is closed via the earth with the
this figure. Power limitation: see end of section result that roving parts of this current can inter-
4! fere with electronic equipment far away from the
drive.
19 Public low voltage lines in industrial
regions 21 Fuses at the stubs from the low volt-
In an industrial region the noise level which is age line
caused by converters is allowed to be 10 dB At the stubs the cross-sections of the conduc-
higher than in a residential region with included tors become lower than in the main cable. There-
light industry. Therefore the protection targets fore fuses are prescribed which are adapted to
concerning EMC can be met without screened the reduced cross section, and they must be
motor cables if these cables are configured located close to the stubs. This principle must be
according to 14 . repeated at each reduction of the cross section
from the stub at the main cable via the distribu-
A public low voltage line of an industrial region tion net in a house or factory down to the
may have an own supply transformer as shown connection point of a converter. The resulting
in fig. 2.1/5, but often the lines of an industrial fuse hierarchy is not shown in fig. 2.1/5. Only the
region and of a residential one are supplied by fuses of the lowest rank are mentioned.
a common transformer. This depends on the
power consumption of both regions and on their
22 Fast Fuses
distance. Power limitation: see end of 4 !
The converters are protected against overload
by their control systems. Therefore dangerous
The dashed line between the lines of both re-
overcurrents can be caused only by faults in the
gions indicates the version with only one trans-
converters themselves or in the loads. In such
former. This dashed line represents a power
cases the thyristors can be protected only with
cable from the transformer at the right to the
the aid of special fast fuses. Such fast fuses are
industrial region at the left. The power cable is
shown directly at the AC connection points of the
important also for the EMC. Due to its length it
converters in fig. 2.1/5 as well as in the connec-
reduces the noise level by at least 10 dB from the
tion example, with more details, at the beginning
industrial to the residential region.
of 24 . But fast fuses outside the converters are
necessary only for units of the lower power
range. Larger converters comprise the fast sem-
20 Industrial low voltage lines iconductor fuses.
Industrial low voltage lines are local lines in
plants or factories. They have own supply trans-
23 Stub for auxiliary devices
formers (see 6 ). In most cases they are insulat-
Examples for auxiliary devices: field supply con-
ed (IT network / no earthed star point) and their
verters, transformers, fan motors.
voltages are often higher than 400 V. The loads
tolerate higher noise levels. Therefore and be-
cause industrial lines are decoupled from public 24 Connection example in accordance
lines by their transformers and distances, con- with EMC
verters do not need EMC filters at industrial low- See fig. 2.1/11.
voltage lines (see 6 ). Problems for other loads
III A 2-11
3ADW000163R0201_Technical guide_e_b
Technical environment
Remarks
28 Internal ground connections
Additionally to the PE connections good HF
connections to ground must be realised with the An additional local earthing, especially at the
aid of a mounting plate which has a well con- motor, raises the level of the RF noise on the line
ducting surface (sheet metal from zinc-plated cable.
steel for example). This means, the housings of
all components like the line filter and the con- Earth connections between motor and driv-
verter must be pressed directly to the mounting en machine
plate by at least four fixing bolts. The seating The earth of a grounded machine must be
surfaces of the housings must be free from non connected to the earth of the driving motor, in
conducting coating. These ground connections order to avoid floating potential.
are indicated in the drawing at the top by the
following symbol (symbol often used to indicate Thermal motor protection
mass or chassis): It is recommended that the cable of thermal
motor protection device is fed through an appro-
priate filter at the point of entry into cubicle, in
order to suppress EMC disturbances.
III A 2-12
3ADW000163R0201_Technical guide_e_b
Technical environment
Mounting plate
L1 U1
I/O
T
Filter
L2 V1 A
C1
L3
PE
W1 M
D1
U1 Field
supply F+
V1 unit F-
F
PE
PE
PE
lower edge
of the PCB F1
carrier
Armature and field F2
cables with A1 A2
Tacho
screens for
"first environment"
prefered solution
directly to
intermediate
terminals
C1/D1 F+/F-
Screens
to filter, choke... Contact to the motor
housing at the whole
screen perimeter
Hint: The armature current cable must contain a third wire
for a PE connection if the copper cross section of the screen
PE cannot fulfil the PE safety demands.
PE bar
A F Tacho
Encoder, analogue I/O,
and digital I/O (>3 m)
DC motor
Mounting plate with PE terminals on the
busbar and terminals CON-x board
F A
lower edge F1
of the PCB Armature and field
carrier cables without F2
screens suitable for A1 A2
Tacho
"second
Screen
environment"
prefered solution
directly to
intermediate
terminals
C1/D1 F+/F-
to filter, choke...
PE
PE bar
A F Tacho
Encoder, analogue I/O,
Important hint and digital I/O (>3 m)
The example shows the principle structure of a DC drive and its connections. It is not a binding
recommendation, and it cannot respect all conditions of a plant. Therefore each drive must be
considered separately and with respect to the special application. Additionally the general
installation and safety rules must be taken into account.
Fig. 2.1/11 Connection example in compliance with EMC
III A 2-13
3ADW000163R0201_Technical guide_e_b
Technical environment
III A 2-14
3ADW000163R0201_Technical guide_e_b
Technical environment
Second environment
The drive complies with the limits of IEC
61800-3 with the following provisions:
III A 2-15
3ADW000163R0201_Technical guide_e_b
Technical environment
III A 2-16
3ADW000163R0201_Technical guide_e_b
3 Engineering of DC drives Engineering of DC drives
3.1 Fusing aspects of DC drives ensure adequate protection. It is, however, def-
initely possible that the fuse will not yet trip
3.1.1 General during one half-wave. Fuse and thyristor, how-
ever, are already suffering preliminary damage,
Protection elements such as fuses or overcur-
which may not become apparent until later.
rent relays are used whenever overcurrents
cannot entirely be ruled out. In some configura- Basic principles
tions, this will entail the following questions: 1. Only semiconductor fuses of matched size
firstly, at what point should which protective can in the event of a fault protect the power
element be well suited incorporated? And sec- semiconductors. Unprotected power semi-
ondly, in the event of what faults will the element conductors may explode and cause the de-
in question provide protection against damage? vice to catch fire.
AC supply: public mains / plant's mains 2. In earthed networks, only semiconductor
Cabinet
fuses in the supply can protect the device in
the event of an earth fault.
3 2
M 3. Well suited semiconductor fuses constitute
. .
. . an optimum protection for the semiconduc-
. .
tors only in "hard" networks. In "soft" net-
works, and in the motor circuit, the protection
For field supply 2 is questionable. In "soft" networks, during
see Fig. 3.1.4/1
regenerative operation, an increased risk of
conduction-through must be anticipated. In
Fa_asp_c.dsf
the motor circuit, high-speed DC circuit-
Fig. 3.1.1/1 Arrangement of the switch-off elements for the breaker constitute optimum protection.
armature supply
4. Semiconductor fuses in the armature circuit
A thyristor can be switched on in a controlled must be dimensioned for DC voltages, so as
manner by a firing pulse, but it cannot switched to assure an adequate spark-quenching gap
off by any command. It will switch-off automato- in the event of a fault. A compromise is provid-
cally when the current drops below the holding ed by two series-connected fuses, as used
current and no firing pulse is generated; it can be in the AC power supply of small modules or
switched off by forcing the current below the the power section of big ones.
holding current. The earliest switch-off moment 5. In 2-Q devices, no circulating current occurs.
is prepared by the next zero crossing of the line If a thyristor failure due to overload or a
voltage half-wave when firing pulses are moved qualitative defect results in a phase-to-phase
to the safe position. Until then, full short-circuit short-circuit, only semiconductor fuses can
current is flowing over the thyristor. The duration protect the device.
concerned will depend on the firing moment 6. In the case of 2-Q devices, in regenerative
within the half-wave, and can already result in mode, conduction-through is possible as in 4-
destruction, or at least preliminary damage. Q operation, with the consequence of over-
current.
U
7. Conventional fuses in the tapered feeder to
the power converter can be replaced by semi-
rectified line voltage
conductor fuses, if the feeder's cross-sec-
tional areas are matched at least to the de-
vice's rated line current (local regulations not
t taken into account). A thermal overload in the
Thyristor disable
will usually be current-limiting. The protect the fested in that a thyristor no longer
converter
maximum current corresponds to the fires or in that it is permanently con-
current limitation set. If this limitation ductive.
feature or one of the requisite com- Basic Principles 1 + 3 + 4 + 5
ponents fails, then the current will +6
frequently rise sharply.
SF2
protect the motor
If one or more than one false firing
pulses are produced, e.g. due to protect the motor
M
Basic Principles 1 + 2 + 3 + 4
Defective system conditions leading to commutation
failure
SF4
In the case of regeneration, the ratio
protect the
of motor voltage and line voltage converter
rises above 1.05, which is followed
by a situation called "shoot-through".
The current rises substantially.
Possible causes include:
network malfunctions (line und-
ervoltage)
overspeed due to the load in-
volved (load accel-erates motor)
or due to a control error protect the motor
III A 3-2
3ADW000163R0201_Technical guide_e_b
Engineering of DC drives
Conclusion
Due to cost saving in some of customer applica- cause very high consequential costs. Exploding
tions standard fuses are used instead of "more power semiconductors may not only destroy the
expensive" semiconductor fuses. Under normal power converter, but also cause fires.
and stable operating conditions, this is even Adequate protection against short-circuit and
understandable and comprehensible, as long earth fault, as laid down in the EN50178 stand-
as fault scenarios can be ruled out. ard, is possible only with appropriate semicon-
In the event of a fault , however, the saving may ductor fuses.
LV HRC LV HRC
Semiconductor Semiconductor standard standard
fuses fuses fuses fuses
only one
Semiconductor semiconductor
fuses fuse
M M M M
Fusing_thyristors_a.dsf
Complies with Basic Principles on: Complies with Basic Principles on:
1 Explosion hazard yes 1 - Explosion hazard no
2 Earth fault yes 2 - Earth fault partly, only
3 Hard networks yes with 4-Q, between
4 Spark-quenching gap yes fuse and motor
5 Short-circuit yes 3 - "Hard" networks no
6 2Q regenerative yes 4 - Spark-quenching gap no
5 - Short-circuit no
6 - 2Q regenerative no
III A 3-3
3ADW000163R0201_Technical guide_e_b
Engineering of DC drives
III A 3-4
3ADW000163R0201_Technical guide_e_b
Engineering of DC drives
III A 3-5
3ADW000163R0201_Technical guide_e_b
Engineering of DC drives
Configuration C Configuration D
Line Line In the case of high power convert-
If an isolation transformer is used,
Connecting it is often possible to comply with Connecting er outputs or high currents, a pow-
point point er converter transformer must fre-
certain connecting conditions per
Configuration B without using an quently be used for voltage match-
additional line reactor. The condi- ing. If an autotransformer is used
tion described in Configuration A for this purpose, a commutating
LLR
will then likewise be satisfied, since reactor must additionally be used if
the uk is >1 %. special conditions must be com-
plied with as per Configuration B,
the reason for this being that the uk
Configuration C1
of commonly used autotransformers is general-
If 2 or more converters should be
Line ly too small. If you do not have to allow for special
supplied by one transformer the
conditions of this kind, you must nevertheless
Connecting final configuration depends on the check whether the uk of the autotransformer
point number of drives in use and their
concerned is sufficient for satisfying Configura-
power capability. Configuration A
tion A.
or B has to be used which are
based on commutation chokes, if
LLR LLR the drive system consists of C1,
C2 or A5 converters. In case only
two converters type A6 / A7 (A6 +
A6, A6 + A7, A7 + A7) are involved no commu-
tation chokes are necessary because the de-
sign of these converters is adapted to that wir-
ing.
III A 3-6
3ADW000163R0201_Technical guide_e_b
Engineering of DC drives
III A 3-7
3ADW000163R0201_Technical guide_e_b
Engineering of DC drives