Load Commutated mutated Inverter (LCI) Medium Voltage Drive 2000/4000 Series Product Guide Rugged, Reliable, Proven Performance For High Power Drive Applications metals cranes mining testing oil & gas mining utilities cement High Efficiency, High Availability LCI Features Benefits Unique Bridge Design Maximized Up-Time – Reliability Each bridge uses full voltage rated devices in an easy to maintain configuration. The standard N+1 SCR redundancy insures full power output even in the event of a device failure. Highest System Efficiency Synch motor and LCI combination give highest efficiency drive system available. Most Cost Effective High HP Systems High efficiency means reduced energy costs for total project life. Input Configuration Power System Friendly Drive can be configured for 6-, 12- or 24-pulse input. Flexibility allows most cost efficient installations. LCI can be used as motor control or for motor starting applications. Water Cooled Technology Compact Quiet Design Fully redundant system, hoses don’t need to be disconnected for bridge service. Reduces maintenance and ambient noise, saves your valuable floor space, allows for transformer to be remotely mounted (outdoors). Windows®-Based Configuration and Maintenance Tools Faster Commissioning and Maintenance For pc-based configuration, the Control System Toolbox features: • Animated block diagrams • Integrated trend window The LCI drive is ideal for any high power synchronous motor application for which adjustable speed operation or soft starting is needed. Adjustable speed operation allows optimal efficiency (energy saving) and improved process accuracy. Typical adjustable speed applications include: • Compressors for air or petrochemical processes • ID fans for coal-fired boilers • Grinding mills • Rod and bar mills • Marine Propulsion These world-class tools drive productivity in commissioning and typical maintenance activities. Volts 4160 2300 2500 4000 Series LCI 2000 Series LCI 5000 10000 13000 18000 80000 hp Soft-starting reduces the mechanical stress on the motor and driven equipment as well as eliminating electrical starting surges on the ac power system. The rating of the starting system depends on the power required to drive the load at synchronous speed. However, because many driven machines can be arranged for reduced load operation during starting, power rating of the starting equipment can be greatly reduced. An output transformer permits the LCI drive to operate with any motor voltage. The LCI drive has a closed transition for synchronizing/de-synchronizing function that means no other synchronizing equipment is needed to smoothly start multiple large motors. Bringing Powerful Control To A Wide Variety Of Industries The LCI drive’s robust power bridge design and long years of proven operational reliability make it the ideal solution for your high horsepower compressor applications. One applications uses LCIs and electric motors to replace gas turbine drives to eliminate emissions, reduce noise, reduce maintenance and increase operational efficiency and control. Compressor Station The LCI drive can be seamlessly integrated with the rest of your pump or compressor station control system. Supporting a variety of Local Area Networks (LAN) and hardwired I/O allows you the flexibility necessary for remote and even un-manned operations. Pump Station The LCI has been used to power many types of grinding mill applications. It can be used to start multiple mills or function as a dedicated power supply to a mill for optimal process control and variability. Grinding Mill Traditional mechanical methods for controlling airflow are inefficient and require considerable maintenance. The LCI provides more accurate and energy efficient control of airflow while eliminating the maintenance associated with dampers or vanes. Any large fan application, like a cement or utility ID fans, will benefit from using the LCI for controlling its synchronous motor. Induced Draft (ID) Fan In the configuration, start-up, and maintenance of large drive systems like ship propulsion, a PC-based programming tool is essential. The LCI utilizes many parts of the TMEIC Control System Toolbox software package. This package is shared across a number of drive platforms and results in reduced customer training time. Ship Propulsion 3 The LCI Drive is Designed to Specifications and Requirements To Meet Your Most Demanding Applications Differentiating Features: • Compact design saves valuable floor space • High reliability, high efficiency design • User friendly and easy to maintain Integral Field Excitation Package for ac Brushless exciters. Optional external exciter control for “across the line” motor operation. Control Panel Source Bridge Panel (Doors Open Showing SCR Cells) Simple, Flexible Controls • VME Rack mounted cards • Extensive Diagnostics • Supports OnSite remote diagnostics services • User friendly displays • Ethernet and other LAN’s Configurable Input/Output • VersaMax I/O modules • Easy customer access for wiring Input Transformer Options • Oil Filled or Dry • Outdoor or Indoor 4 Water Cooled Power Bridge • Design allows quick replacement of SCR devices without disturbing cooling system DC Link Reactor Options • Outdoor or Indoor • Air or Iron Core Construction High Reliability, Water Cooled Drive Benefits • High power in a small footprint • Removing >90% of drive heat allows low HVAC load, saving money over 20+ yr. life • Quiet – less than 70 dBA Load Bridge Panel (Showing Firing Circuit Modules) Pump Panel Redundant Cooling System • Pump autochange over • Maintenance Free Stainless Steel hose clamps • Pump, deionizer, and filter can be changed while running High Reliability Power Bridges • Identical Source and Load Bridge • Full Voltage rated devices • True N+1 SCR Redundancy • Diagnostics down to the cell level • Optical gating insures isolation of medium voltage and low voltage sections Heat Exchanger Options Include • Water to Air (shown) • Water to Water • Redundant Heat Exchanger Fans (shown) 5 Control System Toolbox – A Common Tool Across all TMEIC Drive Products Drive Commissioning with an Integrated Trend Window For knowledge management inside the LCI, the Control System Toolbox provides animated graphic displays of control logic as well as an integrated window for the trending of drive and related process variables. This tool features ease of configuration and data analysis. Trend Configuration • Define a trend with drag and drop of variables from function block diagrams or select variables from a pick list • Conduct online real-time trending with the drive or upload the capture buffers in the drive for trending. For historical trending, define a link with an integrated historian database. Control System Toolbox Screen Shot 6 Display/Analysis • Quickly define a display with the auto-scaling toolbar button • Analyze a specific time frame with the zoom in/out toolbar buttons • Create different views using variable hiding • Analyze specific times with a crosshair • Perform frequency-based analysis of the trend using the fast fourier transform (FFT) function Knowledge Management Options Bring Productivity to Your Operation Customer Support Plant Operations Console Ethernet Plant Operations Key system operating parameters and diagnostic information can be presented to your operations team. 11/02/2005 LOAD AMPS LCI STATUS PAGE 1 LOAD VOLTS 1704 SRC VOLTS SRC BKR CLOSED FLD CON CLOSED BYPASS OPEN ABOVE MIN SPD SIX PULSE RUN REQUEST RUN PER OK START PERM OK DIAG EX TEST ON Local or Remote Human-Machine Interface Example Toolbox Status Screen 13844 TUNE GROUP 1750 NO FAULTS LOAD SW CLOSED GOTO PANEL TREND ALPHA TST OFF LOAD HP 1750 RPM REF 4932 CHANNEL RUNNING 23:00 MOTOR RPM 4050 LINK VOLTS 4160 CHANNEL READY SLAVE CHANNEL GOTO PANEL IN CUR LIMIT 1 ALARM SIM MOD ON COOL NOT OK NO SYNC REQUEST CROWBAR MOD ON LOCAL MODE GOTO PANEL GOTO PANEL GOTO PANEL LOCAL REMOTE COOL SYSTEM MORE STATUS Global Customer Support Network The 24x7x365 customer service can dramatically reduce downtime for your process by providing the fastest Elapsed Time to Repair. Performance Screen Process Optimization Processes cannot be optimized without key information on how the process is currently performing. With the LCI control and optional Human-Machine Interface, key operating drive parameters as well as system performance information are continuously available to plant operations for process optimization. 7 Load Commutated Inverter (LCI) Theory The LCI operation is simple and reliable. It uses load-commutated, phase-controlled power thyristor technology to supply power to the stator windings of a high efficiency synchronous motor. Synchronous Motor 3 SCR Converters Isolation Transformer The power circuit has a source converter, connected to the power supply and a load converter connected to the motor. When motoring, power flows from the power source to the motor. Regeneration is built in, allowing smooth control of loads in all operations. The LCI controls the motor torque to regulate motor speed. Motor torque is controlled through the DC link current. The LCI power converter blocks can be paralleled to deliver ratings in excess of 70,000 HP. Multi-channel output gives low harmonics on the motor and gives the opportunity for single channel operation. Consult TMEIC General Industries for custom systems to meet your requirements. 6 Pulse / 6 Pulse (Possible Multiple Motors) DC Link Inductor DC Link Inductor Synchronous Motor 12 Pulse / 12 Pulse SCR Converters Dual Secondary Transformer 24 Pulse / 12 Pulse Synchronous Motor Option for HV Motor 12 Pulse / 6 Pulse Synchronous Motor Synchronous Motor Option for HV Motor Power Bridge Building Blocks – Multiple Blocks Combine for High HP Applications Output Voltage Source, Load Configurations Power Block Rating – HP Dimensions – mm (in) Weight – kg (lbs) 2300 6-p, 6-p 7,000 4000 x 1400 x 2500 (158 x 55 x 100) 3400 (7500) 2300 12-p, 12-p 14,000 5600 x 1400 x 2500 (220 x 55 x 100) 4100 (9000) 4160 6-p, 6-p 18,000 5600 x 1400 x 2500 (220 x 55 x 100) 4300 (9500) 4160 12-p, 6-p 18,000 5600 x 1400 x 2500 (220 x 55 x 100) 4300 (9500) 1. Rating is based on 40 ˚C water. 2. Dimensions based on arrangement with pump panel and control at opposite ends of lineup. Subtract 1200 mm [47 in] from length if pump panel is placed behind control. This arrangement has no space for integrated field exciter. 8 Control Offerings To Fit Your Application Instrumentation Interface Toolbox Meter Outputs D/A +- 10 V Additional Specifications • RJ-45 Ethernet™ interface • 10 Mbps maximum • ISBus™-Ethernet option using Innovation Series controller as gateway Power System Input and Harmonic Data • Voltage: 3 phase, +10%/-5% continuous • Tolerates power dips to 30% without tripping, complete control power loss ride through of 100 msec with UPS backup available. • Frequency: 50 or 60 Hz • Top or Bottom Cable entry • Motor current A and B, ±10 V • Quantity 5 configurable, ±10 V, 8-bit resolution • Connections via keypad Transformer Options • Outdoor or Indoor • Aluminum or Copper winding • Oil filled or Dry Type • Options for future fans • Up to 132 kv primary input Source Bridge Type • AC fed 6 or 12 pulse SCR, Regenerative, with N+1 devices • N+1 power devices for added reliability I/O Interface Digital Inputs (VersaMax Input Modules) • Standard – 8 inputs, 120VAC • Additional Inputs available as an option Digital Outputs • Standard – 8 outputs, 120VAC (VersaMax • Additional Outputs available as an option Output Modules) Analog Inputs (VersaMax Input Modules) • Standard – 2 inputs, 0-10VDC • Additional Inputs available as an option Analog Outputs • Standard – 2 outputs, 0-10VDC • Additional Outputs available as an option (VersaMax Output Modules) LAN Interface Options • DeviceNet™ • Profibus-DP™ • ISBus • Other available on request A B Speed Feedback Encoder Input Z Supply Excitn Optional Speed Feedback Devices • A quad B with marker • Maximum frequency of 125 kHz • Differential 5 or 15 V dc • 5 or 15 V dc at 200 mA supply A Speed Tach Follower Output Enclosure B +15-48 V • Singled ended A-B • Maximum frequency of 10 kHz • External 12-24 V dc is required • NEMA 1A/IP 21 • Optional Splash-proof louver system • Allow a minimum of 36” for Rear Access for installation and maintenance Load Bridge Type • 6 or 12 pulse output configurations with N+1 devices • N+1 power devices for added reliability Applicable Standards • UL508C, IEC 146-1-2, NEMA ACS 7-1993, CSA C22.2, UL347A, EN50178 Manufacturing Quality Systems • ISO9001, ISO9000-3 Safety Features • Control Optically Isolated from MV circuits for safety • Pad-lockable Doors • Short Circuit Bracing for 30,000 amps Symmetrical Output • 10 – 160% of Rated Speed Control Range • Top or Bottom cable entry Operating Environment • Temperature: 0 to +50 ˚C • Altitude: Up to 14,000' with only small de-rating • Pump and Control Power (by user): 7 kva, 460V/380V, 3 phase, 60/50 Hz Cooling • Liquid Cooled with De-ionized water • Redundant cooling pumps with automatic control • For water/water heat exchangers : 50 ˚C max inlet water temperature • For water/air heat exchangers - options for redundant fans Sound • Less than 70 dBA at 1 meter from enclosure Control • Non-volatile memory for parameters and fault data • Forced commutation below 10% of rated speed • Load commutation above 10% of rated speed • Torque regulated, four quadrant speed control • Volts/Hz control • Field Excitation control • Programmable acceleration/deceleration ramps Control Accuracy • Speed Regulation • Max Starting Torque • Max Forward Speed • Max Reverse Speed • Constant HP Speed Range • Constant Torque Speed Range Protective Functions • Fuse-less design • Overcurrent • Overvoltage No Tach 0.1% 0.75 PU 1.0 PU 0.5 PU Base to Top 0.1 PU to Base Tachometer 0.005% 2.0 PU 1.0 PU 1.0 PU Base to Top 1.5Hz to Base • Over-temperature • Optional Motor RTD monitoring 9 For Existing Lecacy LCI Systems, the TMEIC Control Upgrade Offers Many Benefits The DIRECTO-MATIC® LCI drive has provided reliable Product Life Extension service for more than 20 years. To keep that record intact, TMEIC has developed a control upgrade for the DIRECTO-MATIC drive, while preserving the existing power bridge. In addition to extending the product life, this modernization program provides significant DIRECTO-MATIC Control TMEIC Control functional enhancements plus a system condition and capability assessment of your drive system. DIRECTO-MATIC Control Proprietary wire wrapped backplane system: • 1980s circuit board technology • 80286 processor • I/O integrated with control SCR Power Converter TMEIC LCI Control Upgrade Control Hardware • VME design provides improved reliability and less than half the number of circuit boards • 300Mhz Celeron processor • Modular I/O improves flexibility and diagnostics • Optional Field Exciter control upgrade Hardware dependent control: • Limited sequencer • Fixed block diagram regulator • Terminal emulator Control Software Library • Flexible sequencing logic • Windows®-based Control System Toolbox • Animated graphic displays • Integrated trending window • Common tool across the TMEIC family of system drives Limited control and data interface: • Local control push buttons • Printer • Meters • One serial interface Knowledge Management • Optional local or remote touch screen interface panel • Multiple RS-232™ and Ethernet™ ports • Drivers for ISBus™, DLAN+, Modbus® SRTP, A-B DH+ • Custom HMI Screens Available Service options: • DIRECTO-MATIC trained field engineers • Local diagnostic tools Technical Support Options Current generation technology and connectivity for remote diagnostics means lower Elapsed Time to Repair For more details, see “Modernization of Directo-Matic LCI Drive Systems” Brochure 10 Meeting Your Medium Voltage Drive Needs With A Full Family Of Products TMEIC brings you a wide variety of Medium Voltage products. Our Dura-Bilt5i drive, for induction or synchronous motors, with industry leading warranty, our high power TMdrive-70 IEGT and TMdrive-30 drives, and our control upgrades for existing legacy LCI drives provide a unique family of drive offerings to serve all your Medium Voltage drive requirements. ® DIRECTO-MATIC LCI Drive Systems Dura-Bilt5i MV V Modernization 2000/3000/4000 Series Application Guide metals cranes mining testing oil & gas cement utilities Directo-MaticLCI_2011 Logo Revise.indd 1 paper 9/30/2011 3:35:58 PM LCI Modernization – Control Retrofit Package for extending the life of existing legacy LCI Drive systems. TMdrive-30_Guide_2011_logo_revise.indd 1 mining mining testing oil & gas cement utilities paper Dura-Bilt5i MV® – Air cooled, MV PWM Drive with integral transformer - 200 to 10,000 HP. DB5i2011 logo revise.indd 1 9/30/2011 1:47:37 PM Medium Voltage 3-Level IEGT System Drive Medium Voltage 3-Level IGBT System Drive cranes cranes TMdrive®-70 Product Application Guide TMdrive®-30 Product Application Guide metals metals testing oil & gas paper utilities cement 10/5/2011 11:43:19 AM TMdrive®-30 – High performance, air cooled, PWM System Drive – 100 to 4,500 HP. metals TM70_Ltr Guide_2011_FINAL.indd 1 cranes mining testing oil & gas cement utilities paper 9/30/2011 4:05:44 PM TMdrive®-70 – High Performance, water cooled, PWM System Drive – 5000 to 35,000 HP. 11 TMEIC AC Drives Offer Complete Coverage Global Office Locations: TMEIC Corporation Office: 1325 Electric Road, Suite 200 Roanoke, VA, United States 24018 Mailing: 2060 Cook Drive Salem, VA, United States 24153 Tel.: +1-540-283-2000 Fax: +1-540-283-2001 Web: www.tmeic.com TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION Mita 43 MT Bldg. 13-16 Mita 3 chome, Minato-ku Tokyo 108-0073 Japan Tel.: +81-3-5444-3828 Fax: +81-3-5444-3820 Web: www.tmeic.co.jp TMEIC Europe Limited 6-9 The Square, Stockley Park Uxbridge, Middlesex, United Kingdom UB11 1FW Tel.: +44 870 950 7220 Fax: +44 870 950 7221 Email: info@tmeic.eu Web: www.tmeic.com TMEIC Industrial Systems India Private Limited Unit # 03-04, Third Floor, Block 2, Cyber Pearl, HITEC City, Madhapur, Hyderabad, 500081, Andhra Pradesh, India Tel.: +91-40-4434-0000 Fax: +91-40-4434-0034 Email: inquiry_india@tmeic.in Web: www.tmeic.in © 2011 TMEIC Corporation. All Rights Reserved TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS (Beijing) CORP. 21/F., Building B, In.do Mansion 48 Zhichunlu A, Haidian District, Beijing 100098, PRC TEL: +86 10 5873-2277 Fax: +86 10 5873-2208 Email: sales@tmeic-cn.com Innovation Series is a trademark of General Electric Company. TMdrive is a registered trademark of TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION. TMEIC is a registered trademark of TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION. All other products mentioned are registered trademarks and/or trademarks of their respective companies. All specifications in this document are subject to change without notice. The above brochure is provided free of charge and without obligation to the reader or to TMEIC Corporation. TMEIC Corporation does not accept, nor imply, the acceptance of any liability with regard to the use of the information provided. TMEIC Corporation provides the information included herein as is and without warranty of any kind, express or implied, including but not limited to any implied statutory warranty of merchantability or fitness for particular purposes. The information is provided solely as a general reference to the potential benefits that may be attributable to the technology discussed. Individual results may vary. Independent analysis and testing of each application is required to determine the results and benefits to be achieved from the technology discussed. If you have any questions regarding your project requirements, please contact TMEIC Corporation at 540-283-2000.