Practical Variable Speed Drives and Power Electronics

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1 Practical Variable Speed Drives and Power Electronics Malcolm Barnes CPEng, BSc(ElecEng), MSEE, Automated Control Systems, Perth, Australia AMSTERDAM BOSTON HEIDELBERG LONDON. NEW YORK OXFORD PARIS SAN DIEGO SAN FRANCISCO SINGAPORE SYDNEY TOKYO Newnes is an imprint of Elsevier

2 Contents Preface xi 1 Introduction 1_ 1.1 The need for variable speed drives Fundamental principles Torque-speed curves for variable speed drives Types of variable speed drives Mechanical variable speed drive methods Belt and chain drives with adjustable diameter sheaves Metalic friction drives Hydraulic variable speed drive methods Hydrodynamic types Hydrostatic type Electromagnetic or 'Eddy Current' coupling Electrical variable speed drive methods AC commutator motor - schrage motor Ward-Leonard system Electrical variable speed drives for DC motors (DC drives) Electrical variable speed drives for AC motors (AC drives) Slip control AC variable speed drives Cycloconverters Servo-drives phase AC induction motors 36^ 2.1 Introduction Basic construction The stator The rotor The other parts Principles of operation The equivalent circuit Electrical and mechanical performance Motor acceleration AC induction generator performance Efficiency of electric motors Rating of AC induction motors Electric motor duty cycles 54 S1: Continuous running duty 54 S2: Short-time duty 55 S3: Intermittent periodic duty not affected by the starting process 55

3 vi Contents S4: Intermittent periodic duty affected by the starting process 56 S5: Intermittent periodic duty affected by the starting process and also by electric braking 57 S6: Continuous operation, periodic duty with intermittent load 58 S7: Uninterrupted periodic duty, affected by the starting process and also by electric braking58 S8: Uninterrupted periodic duty with recurring speed and load changes Cooling and ventilation of electric motors (IC) Degree of protection of motor enclosures (IP) Construction and mounting of AC induction motors Anti-condensation heaters Methods of starting AC induction motors Motor selection 66 3 Power electronic converters Introduction Definitions Power diodes Power thyristors Commutation Power electronic rectifiers (AC/DC converters) Line commutated diode rectifier bridge The line commutated thyristor rectifier bridge Practical limitations of line commutated converters Applications for line commutated rectifiers Gate commutated inverters (DC/AC converters) Single-phase square wave inverter Single-phase pulse width modulation (PWM) inverter Three-phase inverter Gate controlled power electronic devices Gate turn-off thyristor (GTO) Field controlled thyristors (FCT) Power bipolar junction transistors (BJT) Field effect transistor (FET) Insulated gate bipolar transistor (IGBT) Comparison of power ratings and switching speed of gate controlled power electronic devices Other power converter circuit components 4 Electromagnetic compatibility (EMC) t Introduction The sources of electromagnetic interference Harmonics generated on the supply side of AC converters Definitions The analysis of the harmonic distortion

4 Contents vii Effects of harmonics on other equipment Acceptable levels of distortion in the mains supply system Methods of reducing harmonic voltages in the power supply Power factor and displacement factor Voltages and current on the motor side of PWM inverters Effect of the high PWM switching frequency on long motor cables Selection of PWM switching frequency High rates of rise of voltage (dv/dt) at inverter output Protection of motors against high PWM switching frequency Compliance with EMC standards EMI (or RFI) filters for PWM inverters Concluding comments about high PWM switching frequency Protection of AC converters and motors Introduction AC frequency converter protection circuits AC and DC under-voltage protection AC and DC bus over-voltage protection Output over-current protection Output earthfault protection Heat-sink over-temperature protection Motor thermaloverload protection Overall protection and diagnostics Operator information and fault diagnostics Electric motor protection Thermal overload protection - current sensors Thermal overload protection - direct temperature sensing 153 > Control systems for AC variable speed drives The overall control system Power supply to the control system The DC bus charging control system The PWM rectifier for AC converters Variable speed drive control loops Open-loop control Closed-loop control Cascaded closed-loop control Vector control for AC drives Basic fixed V/f drives V/f sensorless flux-vector drives (open loop vector) Closed-loop field oriented vector drives Current feedback in AC variable speed drives Methods of measuring current in variable speed drives Current feedback in general purpose VWF drives 175

5 viii Contents Current feedback in high performance vector drives DC bus current feedback Speed feedback from the motor 7 Selection of AC converters Introduction 7.2 The basic selection procedure The loadability of converter fed squirrel cage motors Operation in the constant power region The nature of the machine load The load torque Variable torque machine loads Constant torque machine loads The speed range The inertia of the machine load The requirements for starting The requirements for stopping DC injection braking Motor over-flux braking Dynamic braking Regenerative braking Control of speed, torque and accuracy Selecting the correct size of motor and converter Summary of the selection procedures 205 STEP 1. Specify the initial data for the drive application 205 STEP 2. Selecting the number of poles of the motor 205 STEP 3. Selecting the motor power rating 206 STEP 4. Select a suitable frequency converter 206 STEP 5. Final checks 207 STEP 6. An example of a selection calculation Installation and commissioning General installation and environmental requirements General safety recommendations Hazardous areas Environmental conditions for installation De-rating for high temperature De-rating for high altitude Power supply connections and earthing requirements Power supply cables Cables between converter and motor Control cables Earthing requirements Common cabling errors

6 Contents ix 8.3 Start/stop control of AC drives Installing AC converters into metal enclosures Calculating the dimensions of the enclosure Ventilation of enclosures Alternative mounting arrangements Control wiring for variable speed drives Hard-wired connections to PLC control systems Serial communications with PLC control systems Interface converters Local area networks Commissioning variable speed drives The purpose of commissioning Selecting the correct application settings Selecting the correct parameter settings Special topics and new developments Soft-switching The matrix converter 231 Appendix A Motor protection - direct temperature sensing 233 Appendix B Current measurement transducers 244 Appendix C Speed measurement transducers 248 Appendix P International and national standards 262 Appendix E Glossary 266 Index 277

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