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Make the most of your energy


WWW Seminar November 10, 2009

Make the most of SM your energy

Power Quality and Harmonic Mitigation

Agenda
Overview Harmonic Basics IEEE 519 Conventional Harmonic Mitigation Methods AccuSine PCS Applications & Installation Notes Specification Recommendations Summary

Schneider Electric

-Power Quality Correction Group October 2009

Schneider Power Quality Correction Group

Power Factor Correction and Harmonic Filtering:


Capacitor Systems LV & MV up to 15 kV Fixed, Standard and Detuned Auto Banks AccuSine PCS

Voltage Regulation:
Hybrid VAR Compensator Electronic Sag Fighter

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Harmonic Basics
Resultant Waveform

What are harmonics?


Proliferated by power semiconductor devices Converts power (AC to DC) A harmonic is a component of a periodic wave having a frequency that is an integer multiple of the fundamental power line frequency Characteristic harmonics are the predominate harmonics seen by the power distribution system Predicted by the following equation: Hc = np +/- 1 hC = characteristic harmonics to be expected n = an integer from 1,2,3,4,5, etc. p = number of pulses or rectifiers in circuit
3rdHarmonic 7thHarmonic

5thHarmonic

Fundamental

Harmonic 1 2 3 4 5 6 7 : 19

Frequency 60Hz 120Hz 180Hz 240Hz 300Hz 360Hz 420Hz : 1140Hz

Sequence + 0 0 0 0 + : +

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Multi-pulse Converters

Hc = np +/- 1 Hc = characteristic harmonic order present n = an integer p = number of pulses

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Hn 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49

Harmonics present by rectifier design Type of rectifier 1 phase 2 phase 3 phase 3 phase 3 phase 4-pulse 4-pulse 6-pulse 12-pulse 18-pulse x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x
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Harmonic Basics
Nonlinear loads draw it Example: 6-Pulse VFD

Converter DC bus

Inverter

A B C

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-Power Quality Correction Group October 2009

Harmonic Basics
Why a concern?
Current distortion Added heating, reduced capacity in : Transformers Conductors and cables Heating effect proportional to harmonic order squared Nuisance tripping of electronic circuit breakers (thermal overload) Blown fuses Detrimental to generators Heating of windings Detrimental to UPS UPS cant supply the current

Ih

Loads

Vh = Ih x Zh

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Harmonic Basics
Voltage distortion
Interference with other electronic loads Faulting to destruction Creates harmonic currents in linear loads Generator regulators cant function Shut downs

Ih

Not compatible with standard PF caps


Potential resonance condition Excessive voltage Overheating of PF correction capacitors Tripping of PF protection equipment Shutdown / damage to electronic equipment
Loads

Vh = Ih x Zh

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Total Power Factor


TPF = (DPF) x (Distortion factor) KW DPF = KVAf = Cos 1 1 + THD(I)2

Distortion Factor =

= Cos

TPF = Total or true power factor DPF = Displacement power factor Distortion Factor = Harmonic power factor

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Total Power Factor Example


Variable frequency drive (PWM type)
DPF = .95 THD(I) = 90% (no DC choke & no input line reactor) Distortion Factor =

1 1 + .92

= .7433

TPF = .95 x .7433 = .7061

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How are harmonics handled today?


Mixed bag of objectives
Basis of compliance is mixed THDi, THDv, TDD? IEEE 519-1992? Where is PCC? What level of harmonics is to be attained? How to obtain compliance? Sometimes defined Sometimes open ended Validation Poorly defined By each equipment vendor No Total Responsibility for harmonics Has the User been protected where it matters inside the facility

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Typical Present Situation


Specifications direct manufacturers of nonlinear loads to comply within equipment specifications Manufacturers of nonlinear loads have other concerns
Sell standard equipment at competitive prices Leads to minimized harmonic solutions Leads to misleading information about harmonic performance Leads to operational difficulties e.g. Cant operate on backup generators/UPS Force the IEEE 519 discussion to the utility PCC

Many types of solutions are not compatible


Each manufacturer does his own thing without regard to other solutions Approaches are for my equipment only My simulation is for my equipment only I cant include the others

Total solution not achieved


User has system that exceeds specification objectives Consulting engineers cant get overall compliance

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ANSI Standard IEEE 519-1992


Issues addressed:
THD(V) delivered by utility to user (Chapter 11) THD(V) must be < 5% [< 69 KV systems] Defines the amount of TDD a user can cause (Chapter 10) Based upon size of user in relation to power source Table 10.3 for systems < 69 kV Defines limits for voltage notches caused by SCR rectifiers Table 10.2 Defines PCC (point of common coupling)

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IEEE 519-1992
Defines current distortion as TDD
Total Demand Distortion Largest amplitude of harmonic current occurs at maximum load of nonlinear device if electrical system can handle this it can handle all lower amplitudes Always referenced to full load current Effective meaning of current distortion

Defines voltage distortion as THD


Total harmonic voltage distortion

Does not use THD(I)


Total harmonic current distortion Instrument measurement (instantaneous values) Uses measured load current to calculate THD(I)

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IEEE 519-1992
TDD and THD(I) are not the same except at 100% load As load decreases, TDD decreases while THD(I) increases. Example:

Total I, rms Full load 936.68 836.70 767.68 592.63 424.53 246.58 111.80

Measured Fund I, Harm I, rms rms 936.00 836.00 767.00 592.00 424.00 246.00 111.00 35.57 34.28 32.21 27.23 21.20 16.97 13.32

THD(I) 3.8% 4.1% 4.2% 4.6% 5.0% 6.9% 12.0%

TDD 3.8% 3.7% 3.4% 2.9% 2.3% 1.8% 1.4%


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-Power Quality Correction Group October 2009

IEEE 519-1992 Table 10.3


Current Distortion Limits for General Distribution Systems (<69 kV)
I sc / Iload <20 20<50 50<100 100<1000 >1000 <11 4.0% 7.0% 10.0% 12.0% 15.0% 11<=h<17 17<=h<23 23<=h<35 2.0% 1.5% 0.6% 3.5% 2.5% 1.0% 4.5% 4.0% 1.5% 5.5% 5.0% 0.2% 7.0% 6.0% 2.5% h>=35 0.3% 0.5% 0.7% 1.0% 1.4% TDD 5.0% 8.0% 12.0% 15.0% 20.0%

Isc = short circuit current capacity of source Iload = demand load current (fundamental) TDD = Total Demand Distortion (TDD = Total harmonic current distortion measured against fundamental current at demand load.)

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Harmonic Standards

Most harmonic problems are not at the PCC with utility. Typically harmonic problem occur: Within a facility With generator & UPS operation Where nonlinear loads are concentrated Need to protect the user from self by moving the harmonic mitigation requirements to where harmonic loads are located

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Agenda
I. Harmonic Basics II. Conventional Harmonic Mitigation Methods III. AccuSine PCS IV. Applications V. Specification Recommendations VI. Summary

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Harmonic Mitigation Methods


Typically applied per device
Line reactors/DC bus chokes/isolation transformers 5th harmonic filters (trap filters) Broadband filters Multi-pulse transformers/converters Active front end (AFE) converter

System solution
Active harmonic filter

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Harmonic mitigation methods - (Applied per VFD)


Solution
Increase short circuit capacity C-Less Technology Impedance (3% LR or 3% DC choke) 5th Harmonic filter Broadband filter 12-pulse rectifiers 18-pulse rectifiers Active front end converter

Advantage
Reduces THD(V) Lower TDD Simplified design Less cost Low cost adder Simple Reduces 5th & total TDD Reduces TDD (thru 13th) Reduces TDD Reliable Reduces TDD Reliable Very good TDD Regeneration possible

Disadvantage
Increases TDD Not likely to occur** Compliance is limited Application limited Size limited Compliance difficult Does not meet harmonic levels at higher orders^ Large heat losses Application limited Large footprint/heavy Good for >100 HP Large footprint/heavy Good for >100 HP Large footprint/heavy Very high cost per unit High heat losses

Typical % TDD
Dependent upon SCR*** 30 - 50% TDD 30 - 40% TDD 18 - 22% TDD 8 - 15% TDD 8 - 15 % TDD 5 - 8% TDD

Typical Price Multiplier*


Cost of transformer and installation change out

0.90 - 0.95 1.05 - 1.15 1.20 - 1.45 1.25 - 1.50 1.65 - 1.85 1.65 - 1.85

< 5% TDD

2.0 - 2.5

* Price compared to a standard 6-pulse VFD. ** Utilities and users are not likely to change their distribution systems. *** Increasing short circuit capacity (lower impedance source or larger KVA capacity) raises TDD but lowers THD(V). ^ Can be said for all methods listed.

Harmonic mitigation methods


Solution
Increase short circuit capacity C-Less Technology Impedance (3% LR or 3% DC choke) 5th Harmonic filter Broadband filter 12-pulse rectifiers 18-pulse rectifiers Active front end converter

Advantage
Reduces THD(V) Lower TDD Simplified design Less cost Low cost adder Simple Reduces 5th & total TDD Reduces TDD (thru 13th) Reduces TDD Reliable Reduces TDD Reliable Very good TDD Regeneration possible

Disadvantage
Increases TDD Not likely to occur** Compliance is limited Application limited Size limited Compliance difficult Does not meet harmonic levels at higher orders^ Large heat losses Application limited Large footprint/heavy Good for >100 HP Large footprint/heavy Good for >100 HP Large footprint/heavy Very high cost per unit High heat losses

Typical % TDD
Dependent upon SCR*** 30 - 50% TDD 30 - 40% TDD 18 - 22% TDD 8 - 15% TDD 8 - 15 % TDD 5 - 8% TDD

Typical Price Multiplier*


Cost of transformer and installation change out

0.90 - 0.95 1.05 - 1.15 1.20 - 1.45

AccuSine
1.65 - 1.85 1.65 - 1.85

AccuSine
< 5% TDD

2.0 - 2.5

* Price compared to a standard 6-pulse VFD. ** Utilities and users are not likely to change their distribution systems. *** Increasing short circuit capacity (lower impedance source or larger KVA capacity) raises TDD but lowers THD(V). ^ Can be said for all methods listed.
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Inductors/Transformers/DC Bus Chokes


Description: Converter-applied inductors or isolation transformers. Pros:
Inexpensive & reliable Transient protection for loads 1st Z yields big TDD reduction (90% to 35% w/3% Z) Complimentary to active harmonic control

Cons:
Limited reduction of TDD at equipment terminals after 1st Z Reduction dependent on source Z

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5th Harmonic Filter (Trap Filter)


Inductor (Lp) and Capacitor (C) provide low impedance source for a single frequency (5th)
Must add more tuned filters to filter more frequencies Zs Ls Lp C Load

Inductor Ls required to detune filter from electrical system and other filters If Ls not present, filter is sink for all 5th harmonics in system If Ls not present, resonance with other tuned filters possible Injects leading reactive current (KVAR) at all times may not need

Vs

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Broadband Filters
L L Lp C

~
Source

Load

Mitigates up to 13th order or higher Each inductor (L) > 8% impedance V drops ~ 16% at load Trapezoidal voltage to load Can only be used on diode converters Prevents fast current changes (only good for centrifugal loads) When generators are present, re-tuning may be required Capacitor (C) designed to boost V at load to proper level (injects leading VARs) Physically large High heat losses (>5%) Series device

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Multi-Pulse Drives
Description: Drives/UPS with two (12 pulse) or three (18 pulse) input bridges fed by a transformer with two or three phase shifted output windings. Pros:
Reduces TDD to 10% (12 pulse) & 5% (18 pulse) at loads Reliable

Cons:
High installation cost with external transformer Large footprint (even w/autotransformer) Series solution with reduction in efficiency One required for each product Cannot retrofit

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Harmonic mitigation methods


VFD mitigation topologies 6-Pulse converter
DC Link Reactor

12-Pulse converter
+
A

18-Pulse converter
Multipulse Transformer A Line Reactor
9 1 2

Rectifier Assembly DC+

DC Bus

Load

B C

M
AC Line Delta

Wye

4 7

DC-

Transformer Tertiary

Delta

C-less or 3% reactance min (if included); small footprint, simplified cabling

Externally mounted 3 winding transformer; more wire and cabling; complicated


A
100 0

Large footprint, more steel & copper (losses)

A
100 0

A
100 0

6 pulse

12 pulse
0.0s 0.02s

18 pulse

Current waveform distorted TDD 30% to 40% with 3% reactor (depending on network impedance)

Current slightly distorted TDD 8% to 15% (depending on network impedance)

Current wave form good TDD 5% to 7% (depending on network impedance)

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Active Front End (AFE) Converters


Used in UPS and VFD Replaces diode converter with IGBT converter The hype Input Filter Required to limit THDv to <5%
A C S o u r c e Permits current smoothing on AC lines (< 5% TDD) Permits 4-quadrant operation of VFD Maintains unity TOTAL PF Meets all harmonics specs around the world

VFD
IGBT DC Bus IGBT

Filter
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Converter

Inverter

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AFE Converters
Significant harmonics above 50th order American Bureau of Shipping (ABS) requires examination to 100th order when AFE applied

Higher frequencies yield higher heating of current path & potential resonance with capacitors

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AFE Converters
Cons
Larger and more expensive than 6 pulse drives Approximately twice the size & price Mains voltage must be free of imbalance and voltage harmonics Generates more harmonics Without mains filter THD(V) can reach 40% Requires short circuit ratio > 40 at PCC Switched mode power supplies prohibited Capacitors prohibited on mains IGBT & SCR rectifiers prohibited on same mains No other nonlinear loads permitted

200 KVA rated AFE VFD PWM VFD DC Drive PF caps

100 KVA rated

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Agenda
I. Harmonic Basics II. Conventional Harmonic Mitigation Methods III. AccuSine PCS IV. Applications V. Specification Recommendations VI. Summary

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The System Solution


The System Solution:
Single point of responsibility for the total harmonics One specification for harmonic definitions One validation responsibility and guarantee

Standard nonlinear products


3% input line reactors on most non-linear devices, 3% DC bus choke okay for PWM VFD
Limits rms current at load for diode rectifiers Avoids interaction with snubber circuit for SCR rectifier

Best cost and performance

Compatible with all nonlinear products


Compliance with harmonic specifications Controls harmonic levels with facility

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Schneider Electrics Solution


AccuSine Power Correction System (PCS)
Active harmonic filter Provides 5% TDD per load or system Cancels everything from 2nd to 50th harmonic order Used on any/all nonlinear load Active reactive current correction Does not use PF capacitors Used to correct Displacement PF In conjunction with or independent of harmonic control (dual mode) High-speed reactive power

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Active Harmonic Filter System Solution


Applied to one or many nonlinear loads
VFD, UPS, UV, DC drives, DC power supplies

Provides DPF correction More cost effective for multiple loads


For two or more drives, AccuSine and 6 pulse drive combination has lower initial and operating costs than 18 pulse drives For installations with redundant drives, size AccuSine for the operating drives only

Saves space Lower heat losses Not critical to operation


Parallel connected

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Comparison of 18-P VFD to AccuSine PCS + standard VFD


Footprint required
AccuSine PCS+ Std VFD less than 18-P VFD (w/autotransformer) for all conditions

Heat losses
AccuSine PCS+ Std VFD less than 18-P VFD Exception at single units of 50-75 HP, advantage 18-P VFD

Less costly to operate AccuSine PCS+ Std VFD


Less site cooling required with AccuSine PCS + Std VFD

Price (first cost)


When more than one VFD, AccuSine PCS + Std VFD always beats 18-P VFD If only one VFD involved, 300-500 HP sizes favor 18-P VFD

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AccuSine Active Harmonic Filter


Is Ia CT Il

~
Source

AHF
Parallel connected Is + Ia = Il

AHF

Load

Ia includes 2nd to 25/50th harmonic current Is <5% TDD


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AccuSine PCS Power Diagram


IGBT Module
C C C

Pre-charge Contactor
Fuse

S1

S3

S5

AC Lines

Fuse Fuse

Line Inductor

DC Bus Capacitors
+ C

Inductor

Filter Board
S2

S4

S6

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System Solution
AccuSine PCS Sizing Example A 125 HP variable torque 6-pulse VFD with 3% LR
Required AHF filtering capability = 47.5 amperes

Two 125 HP VT 6-pulse VFD w/3% LR


Required AHF size = 84.4 amps

Three 125 HP VT 6-pulse VFD w/3% LR


Required AHF size = 113.5 amps

Six 125 HP VT VFD w/3% LR


Required AHF size = 157.6 amps (not 6 x 47.5 = 285 amps)

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AccuSine Performance
At VFD Terminals AccuSine injection

Source current

Order Fund 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 TDD

AS off AS on % I fund % I fund 100.000%100.000% 0.038% 0.478% 31.660% 0.674% 11.480% 0.679% 0.435% 0.297% 7.068% 0.710% 4.267% 0.521% 0.367% 0.052% 3.438% 0.464% 2.904% 0.639% 0.284% 0.263% 2.042% 0.409% 2.177% 0.489% 0.293% 0.170% 1.238% 0.397% 1.740% 0.243% 0.261% 0.325% 0.800% 0.279% 1.420% 0.815% 0.282% 0.240% 0.588% 0.120% 1.281% 0.337% 0.259% 0.347% 0.427% 0.769% 1.348% 0.590% 35.28% 2.67%
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700 HP Drive AccuSine ON OFF

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700 HP Drive AccuSine ON OFF

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700 HP Drive AccuSine ON OFF

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700 HP Drive AccuSine ON OFF

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700 HP Drive AccuSine ON OFF

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Applications
Most common VFD sites
Centrifugal pumps and fans Pumping Stations Potable Wastewater Wastewater Plants Water Purification (potable)

Disinfectant Systems
UV systems (ultraviolet)

Electronic ballasts 3
Ozone generators (SCR power supplies)

Industrial in-rush support

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AccuSine PCS Specifications

Universal Application
208 480 VAC No user action required to set Highly customized transformers for higher voltages (to 15 kV) 50 or 60 Hz

Fuse protected (200,000 AIC) UL 508 & CSA approved CE EMC - 400V Logic ride through 1 to 10 minutes

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Specification Discussion
Write a specification in Section 16 for an active harmonic filter
Specify any points of concern for insertion of AHF Size of AHF Located per electrical bus Specify total responsibility for all harmonics in facility Specify TDD levels desired at each location 5% TDD guarantees 5% THDv (caused by the loads) with any source Specify compliance tests for each location

Write standard nonlinear load specification


Reduces harmonic incompatibilities and product interactions Need 3% impedance on each nonlinear load

Universal solution
Good for all nonlinear loads Apply AccuSine per electrical bus (best economics)

Can attain 5% TDD per load or bus inside the plant


Avoids harmonic problems both TDD and THD(V)

Write TDD specs not THD(I) at 5%


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AccuSine Tools
Internet Tools
Active Filter Guide Spec (www.reactivar.com) Stand alone spec section (Section 16) Includes harmonic and PF correction requirements Selection Program (www.squaredleantools.com) Easy selection based upon loads not source (same selection for utility or generator) Simple tool to use We guarantee results if used properly during design/layout stage Brochure Application Notes Water/wastewater and other applications Installation Bulletin Best/total information for consultant MCC Selector

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Product Package
Standard (UL only) Enclosed NEMA 1
50 amp 48H x 21W x 19D, 250 lbs 100 amp 65H x 21W x 19D, 350 lbs Wall mounted 300 amp 75H x 32W x 20D, 775 lbs Free standing

Chassis & NEMA12 Also Available

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Product Package
International enclosures
NEMA 12, IP30, IP54 50 amp 75(1905mm) x 31.5(800mm) x 23.62(600mm) Weight 661Ib(300Kg) 100 amp 75(1905mm) x 31.5(800mm) x 23.62(600mm) Weight 771Ib(350 Kg) 300 amp 91(2300mm) x 39.37(1000mm) x 31.5(800mm) Weight 1212Ib(550 Kg) Free standing with door interlocked disconnect CE Certified, C-Tick, ABS, UL, CUL

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Product Re-packaging
Maximum ambient into air inlet 400C Must meet air flow at inlet of AccuSine
50 amp 300 CFM 100 amp 500 CFM 300 amp - 1250 CFM

Heat released
50 amp 1800 watts 100 amp 3000 watts 300 amp 9000 watts

DIM considerations required


On chassis Remote with cable

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Product Re-packaging
MCC Packaging
50 & 100 amp models only Requires one vertical 20 x 20 section Includes circuit breaker

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AccuSine PCS Current Transformers


AC lines
Class 1 400 Hz Four sizes 500:5/1000:5/3000:5/5000:5 Stock split core round units

Added to AccuSine (when parallel connected & source sense)


Use solid core at equal ratio as AC lines CT

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AccuSine PCS Performance


Load(s) DEFINITIONS Is = source current Ias = AccuSine current Il = total load current (vector representations)
Ias

Source

XFMR
Is Il

AccuSine Logic Is + Ias = Il AccuSine injects the harmonics the loads want
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AccuSine PCS Performance


Obtain 5% TDD (current distortion) Overall 10:1 attenuation Cos = .998 Obtain near unity lagging DPF (Cos Optional: Inject to obtain a user set point Either or both functions VAR compensation 100 second detect-to-inject Dynamic response cycle to full control for step load changes

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AccuSine PCS Overall Performance


Harmonic compensation
2nd through 50th order Includes inter-harmonics Independent of source impedance Selection and operation same whether on AC line or backup generator or UPS output

Reactive current injection


Secondary function to harmonic mode Defaults to unity lagging set point Injects leading or lagging reactive current

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AccuSine PCS Cos Performance


In dual mode (Cos + Cos )
Reactive current injection is secondary to harmonic mitigation

Activation of Cos in the field via DIM Default to unity lagging Cos
Can enter a set point (i.e. 0.90 lagging) Can inject leading (capacitive) or lagging (inductive) reactive current

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Dual Mode Operation


Ias =
Ih2 + Ir2

Ias = rms output current of AccuSine Ih = rms harmonic current Ir = rms reactive current
Ias 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 Examples Ih 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0 95.0 Ir 99.5 98.0 95.4 91.7 86.6 80.0 71.4 60.0 43.6 31.2

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AccuSine PCS Installation Considerations


(When in harmonic mode does not apply for reactive mode-only)

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AccuSine PCS Installation Considerations


For Optimal Performance:
Impedance 3% input line reactors (minimum) on every nonlinear load Transformer, 3% DC bus choke for PWM VFD or long power cables (not encapsulated type) can substitute for line reactors Standardizes selection of AccuSine Diode rectifiers: Need to limit rms current at load (limits rise of Ihrms at load) Thyristor rectifiers: Need to protect snubbers (capacitors) on thyristor No capacitors downstream of CT

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AccuSine PCS Installation Considerations


Main Left

Main-tie-main
Tie

Main Right

CBml

CTml CBal

CTtl

CTtr CBar

CBmr CTmr

AccuSine L

AccuSine R

This configuration provides individual AccuSine operation per side regardless of breaker positions.

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Summary
Universal solution
Good for all nonlinear loads (3-phase) Apply AccuSine per electrical bus (best economics)

System Solution
Can attain 5% TDD per load or bus inside the plant Guarantees 5% THDv Requires 3% impedance at loads

Selection based upon loads


Easy to use on-line tool www.squaredleantools.com

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Thank You !

Questions?

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