Harmonics Mitigation Solution & Myths

By Gaurav Raut
Manager – Business Development
HVAC & Key Accounts
Fuji Electric India Pvt. Ltd.
 Index
Harmonics Mitigation
Basics of Harmonics Applying Solution
standards Techniques
• What is • IEEE 519, 2014 • DC Reactor • Technical
Harmonics • IEC / EN61000 - 3 • AC Reactor Compliance
• Source of • AC + DC Reactor • Selecting right
Harmonics • 12 Pulse Tx solution for HVAC
• Generation of • 18 Pulse Tx
Harmonics
• Passive Filter
• Measurement of
• Active Filter
Harmonics
• Active Front End
• Current & voltage
harmonics
• Effects of
Harmonics
 Harmonics

Voltage
• The power grid normally experiences huge variations of load and dip
reacts to changes in the voltage waveform. Power
interruption
Voltage
rise
Transient
over-voltage
Harmonic
• Causes of power disturbances range from electrical switching distortion
circuits to lightning.
Commutation
dips/notches
• Harmonic distortions are repetitive and continuous deformations Voltage
of the voltage or current waveforms.
fluctuation
Frequency
• All distortions result in deviations from the ideal sinusoidal fluctuation
waveform.
Harmonics

Linear Load Non Linear Load

• Induction Motor • Variable Frequency Drives
• Incandescent lamps • Uninterrupted Power Supply
• Heaters etc. • Switch Mode Power Supply
• Welding machines
• LED lightings etc.
Harmonics

Linear Load Non Linear Load

HVAC system overview

~10% ~10%

~20% ~40%

~30% Facility HVAC

~60%

~30%

HVAC Lighting Other Chiller AHU Pumping Cooling Tower

Noise

50 Hz 2 kHz 100 kHz 150 kHz 30 MHz 1 000 MHz

HARMONICS
• Conducted
• Immunity and Emissions
• IEC/EN 61000-3-12
• IEEE 519 - 2014
EMC
• Conducted and Radiated
• Immunity and Emissions
• IEC/EN 61800-3
VFD Circuit diagram
 Harmonics generation
Vab Vac Vbc
IDC

1 2 3
~ a
~ b
~ c VDC
VDC

4 5 6

Ia
• The basic 6-pulse rectifier draws a non sinusoidal
current.
Ib
• A pulsating current is drawn from supply grid.

• Current pulse shape is dependent on capacitor size. Ic

• Current pulse shape is also load dependent.

 Harmonics generation
IDC

DC Bus Voltage
1 2 3
~ a
~ b
Capacitor Current
~ c VDC

4 5 6
Voltage

Voltage
• Sudden increase in current, cause voltage distortion dip
or voltage harmonics
Harmonics generation
 Harmonics generation

Example of harmonics spectrum for a 3 phases and

single phase supply
 Effect of Harmonics
Current Harmonics
• Increase load current on transformer
• Nuisance tripping of electronic protection relays and circuit breakers.
• Degradation of Power factor
• Failure of power factor correction capacitors.
• Temperature rise in connecting power cables. Insulation failure
• Failure of the neutral current carrying conductor in the supply transformer due to unbalanced single phase non-linear
loads.

Voltage Harmonics
• Malfunctioning of sensitive electronic equipment.
• Premature ageing of equipment.
• Increased EMI generation in the power system.
• Increase in core losses in motors which are directly operated from the utility supply
• Increased torque ripple in drive motors directly operated from the utility supply
 Effects of Harmonics

• Voltage Harmonics will be generated where current

harmonics is present
• Voltage Harmonics is system dependent Component &
Current Harmonics is load dependent component Voltage Harmonics
• Level of Voltage harmonics is directly proportional to Distorted Voltage
System impedance

Current Harmonics
Voltage Harmonics
Distorted Voltage
 Effects of Harmonics
Increase current
• Motor load 55KW (Linear load)

• VFD load 55KW (Non linear load)

Tx Tx
• VFD with DC Link Reactor, generate 40% Harmonics

Motor Rated current without VFD

89.68Amp 90.12A = (55 × 1000)/(415 × 1.73 × 0.85)
90.12Amp
VFD Input Current (Fundamental)
83.26A = (55 × 1000)/(415 × 1.73 × 0.92)

VFD VFD Input Current with Harmonics

𝐼𝑅𝑀𝑆 = 12 + 𝑇𝐻𝐼𝐷2 × 𝐼𝑓

55KW 89.68 = 12 + 0.42 × 83.26

55KW
 Effects of Harmonics
600
• Displacement power factor close to unity
Vc
(Cosø 0.98)
400
• True Power factor > 0.9 U 13 U 12

200
1
pfTRUE  I main
1 + (THiD / 100)² 0

V1
-200
True Power Factor
THiD (%)
(Approx)
-400
45% 0.91
- Vc
40% 0.93
-600
30% 0.96 0.04s 0.05s 0.06s 0.07s 0.08s

5% 1.00 The current is almost in

phase with the simple
main voltage
So the Cos Phi is near
from 1
Harmonics Standards

• IEEE 519 & PCC

• PCC = Point of Common Coupling
Medium Voltage Level

Low Voltage - Plant Level

Equipment Level
 Harmonics Standards
Myth: VFD shall meet IEEE 519, THID < 5% at Drive input side

Distortion limits for system from 120V to 69KV

h < 11 11h<17 17h<23 23 h<35 35  h < 50 TDD
Isc/IL
(%) (%) (%) (%) (%) (%)
<20 (*) 4 2 1.5 0.6 0.3 5
20<50 7 3.5 2.5 1.0 0.5 8
50<100 10 4.5 4 1.5 0.7 12
100<1000 12 5.5 5 2 1 15
>1000 15 7 6 2.5 1.4 20

Individual • Maximum harmonics current distortion in

THVD percentage of IL
Bus voltage at PCC harmonic
(%) • Individual harmonics order (odd
(%)
harmonics)
V ≤ 1 kV 5.0 8.0 • Limits for TDD as a function of Isc/IL ratio
1 kV < V ≤ 69 kV 3.0 5.0 at the measurement Point of Common
69 kV < V ≤ 161 kV 1.5 2.5 Coupling
161 kV < V 1.0 1.5 • ISC = maximum short circuit current at PCC
• IL = maximum demand load current at PCC
under normal operating load conditions
 Calculate ISC / IL
Transformer ABC Ltd. Steps

KVA 2000 KVA 2000 × 1000

1. Calculate secondary current 2785.7 =
Primary voltage Volt 3 × 415
11000
Primary current 105 Amp 2785.7
2. Calculate Isc 44,571.3 =
Secondary voltage 415 Volt (6.25ൗ100)
Secondary current 2786 Amp
Impedance (Z) 6.25 % 1400 × 1000
3. Maximum load demand, 1400KVA 1950.0 =
3 × 415

44,571.3
Formulas 𝐾𝑉𝐴 × 1000 4. Isc / IL Ratio 22.86 =
𝐼𝑠𝑒𝑐 = 1950
3 × 𝑉𝑠𝑒𝑐
𝐼𝑠𝑒𝑐
𝐼𝑠𝑐 = KVA 1,400.00 1,200.00 1,000.00 800.00 600.00 400.00
(𝑍ൗ100) Current (Amp) 1,950.00 1,671.43 1,392.85 1,114.28 835.71 557.14
Isc / IL 22.86 26.67 32.00 40.00 53.33 80.00
 Harmonics Standards
IEC / EN61000-3-12

Minimal Rsc I5 I7 I11 I13 THID PWHD

33 10.7 7.2 3.1 2 12 28

 120 40 25 15 10 48 45

At product Level
• EN61800-3 Variable Speed Drives
• EN61000-3-2 <=16A
• EN61000-3-12 16 to 75A
• EN61000-3-4 16A <
(Typically measured up THiD 40th, 2,5 min test period, Rsce dependent)
Harmonics mitigation techniques for drives
Harmonics mitigation techniques for drives
DC Inductors
• THID 40% ~ 45%

• Low cost of investment

• Integrated part of VFD, no separate installation required

DC-Inductors • The added Inductive Reactance reduces the total

reactance caused by the rectifier circuit and DC
capacitors.

• Displacement Power Factor or cosΦ ≈ 1

HARMONIC CURRENT • Poor performance at part load

Fund. 36.22 A
THiD 42.51%
RMS current 39.47 A
Harmonics mitigation techniques for drives
AC Inductors
• THID 40% ~ 45%

• Low cost of investment

• Installed at Drive input side in series with power supply

AC-Inductors
• The added Inductive Reactance reduces the total
reactance caused by the rectifier circuit and DC
capacitors.

• Displacement Power Factor or cosΦ ≈ 1

HARMONIC CURRENT
Fund. 36.84 A • Poor performance at part load
THiD 43.84%
RMS current 40.22 A
• Added impedance to grid, increase voltage harmonics
Harmonics mitigation techniques for drives
AC + DC Inductors
• THID 30% ~ 35%

• Low cost of investment

• AC Reactor Installed at Drive input side in series with

AC-Inductors power supply & DC

• The added Inductive Reactance reduces the total

reactance caused by the rectifier circuit and DC
capacitors.

HARMONIC CURRENT
• Displacement Power Factor or cosΦ ≈ 1
Fund. 36.84 A
THiD 43.84%
RMS current 40.22 A
• Poor performance at part load

• Added impedance to grid, increase voltage harmonics

Harmonics mitigation techniques for drives
12 Pulse Rectifier • THID ~ 12%

• High cost of investment

• Required dedicated 18 pulse transformer (Primary ∆,

Secondary ∆ + Y)

12-pulse rectifier
• Required 12 pulse configured VFD Suitable for higher
power ratings (Typically 110KW & above)

• It target 5th& 7th Harmonics

HARMONIC ANALYSIS
Fund. Current 36.11 A
THiD 17% (11%)
RMS current 36.32 A
Harmonics mitigation techniques for drives
18 Pulse Rectifier • THID ~ 5%

• High cost of investment

• Required dedicated 18 pulse transformer (Primary ∆,

Secondary -20% 0% +20% phase shift)

• Required 18 pulse configured VFD Suitable for higher

18-pulse rectifier power ratings (Typically 110KW & above)

• It target 5th, 7th, 11th & 13th Harmonics

HARMONIC ANALYSIS
Fund. Current 36.05 A
THiD 8.9% (5%)
RMS current 36.28 A
Harmonics mitigation techniques for drives
Passive Filters • Combinations of Inductors and Capacitors reduces all
harmonics, not just low orders.

• Highly dependent on load matching. Too large a filter for

a load leads to power inefficiency.

• Lowest cost of ownership in low power installations.

Passive Filter
(Also called Harmonic Trap Filter)
• Available in 2 variants
• THiD < 10% & THID < 5%
AH F 005 AH F 010
Harmonics mitigation techniques for drives
Active Filters • Offers high performance mitigation

• The filter cancels the distortion by sensing it and

inserting an equal signal with the opposite phase.

• Tolerant with load and grid imbalances

• PCC1, PCC2 and PCC3 installation possible.

• Allows for group compensation, power factor correction

and load balance correction.
Active Filter
 Harmonics mitigation techniques for drives
Active Filters
~
~
~ Load

Voltage waveform

Control

◼ L-C Circuits can reduce high frequency distortion.

Current waveform
Harmonics mitigation techniques for drives
Active Filters

Installation and Compensation

• Central compensation and Retrofit.

• Group compensation.

• Individual compensation for High

Power drives.
Harmonics Standards – IEC / EN61000-3-12
Active Front End • Utilizes Pulse Width Modulation (PWM) in the rectifier
section.

• An electronic control circuit sensors and adjusts the

PWM for optimum control of the DC bus voltage and
harmonic reduction.

• Offers highest mitigation performance.

• Tolerant against load and grid imbalances.

Active Front End - AFE

• The only design for optimum regeneration of power.

• Small & compact.

• Can produce high frequency disturbances.

Harmonics Standards – IEC / EN61000-3-12
Active Front End

Switch frequency
Voltage waveform can be seen on
signal.

Current waveform
◼ L-C Circuits can reduce high frequency distortion.
Harmonics Standards – IEC / EN61000-3-12
Active Front End

Switch frequency
Voltage waveform can be seen on
signal.

Current waveform
◼ L-C Circuits can reduce high frequency distortion.
Summary - Solutions
140%

120%
120%

100%
85%
80%
THID (%)

60%
45% 45%
40% 40%
40% 35%
30%

20% 15%
8% 10%12% 8%
5% 5% 6% 5% 5% 3% 3%
0%

Mitigation Techniques

Minimum THID (%) Maximum THID (%)

Myth
Applying right solution
Information required to check IEEE 519 compliance

• Transformer name plate data

• Total non linear load data
• HVAC Drives (AHU, Pumps, Cooling Tower, Chillers etc.)
For Selection of • Elevators / Escalators Drives
Active Harmonics Filter • Uninterrupted Power Supply (UPS)
• LED Lighting
• Total linear load data
• Motor with DOL / Star-Delta etc.
• Cable length data (Cable size & length)
• Transformer to PCC
• PCC to various loads etc.
 Applying right solution
Use of Passive Harmonics Filter for Harmonics mitigation at Drive
input side
Tx
• Increase total cost of ownership (Depend on Total drive load)

• Increase no. of component, reduce system reliability

• Components like Capacitor in PHF required frequent

maintenance at later stage

PHF PHF PHF • Leading power factor at lower load

• Oversizing of PHF caused poor Performance at part load

conditions
LHD
• Need Bypass system in case of failure
VFD VFD VFD AHF/AFE
• Required separate display for monitoring
AHU / Pumps / Cooling Towers Chillers LHD: Low Harmonics Drive
AHF: Active Harmonics Filter
AFE: Active Front End
PHF: Passive Harmonics Filter
Applying right solution
Use of Active Harmonics Filter for Harmonics mitigation
Tx at Drive input side

• Dynamic compensation system provide good results

at all load conditions
AHF
• Small foot print

• Improve Power factor & line balancing

• Lesser heat loss

• Online engage or disengage possible (check with

manufacturer)
LHD
VFD VFD VFD AHF/AFE • Online display available

LHD: Low Harmonics Drive

AHU / Pumps / Cooling Towers Chillers AHF: Active Harmonics Filter
AFE: Active Front End
PHF: Passive Harmonics Filter
 Applying right solution
Heat Load Hrs / Day Day / Yrs
Total
KW Qty. VFD AHF Total 16 261 Passive Harmonics Filter
Watt Watt KW KW KW KW 40,000INR / Unit X 110 =
1.5KW 101.0 46.0 131.0 0.18 2.83 739.15 74,654.35
44,00,000INR
2.2KW 9.0 46.0 131.0 0.18 2.83 739.15 6,652.37
Total Heat Loss (KW) 81,306.72
Loss in INR (INR/KW) 8.00 6,50,453.76 Active Harmonics Filter
(200Amp)
Heat Load Hrs / Day Day / Yrs Approximate Cost
Total
KW Qty. VFD AHF Total 16 261 10,00,000INR
Watt Watt KW KW KW KW
1.5KW 101.0 46.0 0.05 0.74 192.10 19,401.70 *Approximate market price
2.2KW 9.0 46.0 0.05 0.74 192.10 1,728.86
200Amp 1.0 5,000.0 5.00 80.00 20,880.00 20,880.00
Total Heat Loss (KW) 42,010.56
Loss in INR (INR/KW) 8.00 3,36,084.48

Saving Heat Loss (KW) 39,296.16

Saving / Annum (INR) 3,14,369.28
 Summary

• Passive Harmonics Filter is suitable for smaller system with less quantity of drives

• VFD helps to optimised load of oversized components, VFD operate at part load conditions, PHF exhibit poor
performance at part load conditions

• Active Harmonics Filter provides better efficiency & cost for bigger projects

• Further optimisation can be done for Active Harmonics filter by measuring actual load

• At part load Active Harmonics filter can be used for Power factor improvement & line voltage balancing
IORA 3000 – Active Harmonics Filter
IORA 3000
IEEE519 complied

1. Range 60A to 800Amps

2. Supply Voltage: 400V, 480V, 575V & 690Vac
3. 7” Graphical touchscreen
1. Built in oscilloscope for voltage & current
2. Monitor load & source power
3. Phase voltage, current, power factor, power etc.
4. Built in real time clock
5. Alarm log with time stamping
6. FFT analysis, individual phase harmonics
7. Module health monitoring
8. Password protected
4. Design at 40 deg C. up to 50 deg C. with deration
5. Modular construction, with provision of individual isolation
6. Selective harmonics compensation
7. Priority selection: Power factor correction / Harmonics attenuation
8. Communication port: Ethernet (TCP/IP)
9. Event log with backup memory (memory card, scope with customer)
 Solar Inverter
3 Ph, 415Vac, 50Hz
BMS
• Variable Frequency Drives
UPS Active • Active Harmonics Filter
Harmonics • Uninterrupted Power Supply
Solar Cell Filter • Human Machine Interface
• BTU Meter

Communication Bus
UPS Power supply
Power supply

Multi-pump CPM
Cascade
Control VFD
AHU System
Control
HVAC system AQUA HVAC
VFD
VFD BTU VFD
Monitoring

AHU / Fan Primary, Secondary Chiller / Compressor Cooling Tower

Condenser Pump