Power Quality Solutions , Thomas Liu 劉佳炘 0955-614-833
Power Protection Products
PCS100 AVC
( Active Voltage Conditioner )
© ABB Group
April 13, 2015 | Slide 1
No Protection From PQ Events 未經保護的電力品質事故
Utility
電源
© ABB Group
April 13, 2015 | Slide 2
Home
Who Needs An AVC? 誰需要AVC ?

Factories, facilities and commercial operations that
are dependant on a good quality power supply so
they can produce quality products without
interruption need the ABB AVC.

高度要求電力品質的工廠、設備與公司行號。當這
些客戶的連續生產受到中斷時，產品品質會受到很
大影響。這些場合非常需要AVC解決方案。
Home
© ABB Group
April 13, 2015 | Slide 3
PCS100 AVC Sag (Dip) Protection 電壓驟降保護
Utility Sag
電壓驟降
Injection
Transformer
注入式變壓器
Bypass
旁 路
Rectifier and Inverter
整流和逆變
AVC Structure
© ABB Group
April 13, 2015 | Slide 4
Home
PCS100 AVC Swell Protection 電壓驟升保護
Utility Swell
電壓驟升
Injection
Transformer
注入式變壓器
Bypass
旁 路
Rectifier and Inverter
整流和逆變
AVC Structure
© ABB Group
April 13, 2015 | Slide 5
Home
Industries and Examples 產業範例

Semiconductor 半導體
Chip Manufacturing (Vacuum pumps, Lithography, RFI machine)
晶片製造（真空泵浦，光刻，RFI設備）

Oil
石油

Test and Assembly (Regulated voltage for reliable testing)
測試和封裝步驟（需要穏定的電壓以保證測試的可靠度）

Gas
氣體

Flat Panel Displays (LCD or Plasma) 平板顯示器（液晶或電漿）

Photovoltaic (PV) 太陽能電池

Polysilicon (wafer saw damage and polishing)
多晶矽（矽晶切割線損壞和拋光）
Textile (loom protection) 紡織（織布機保護）

Hospital 醫院
MRI scanners etc (prolongs life) 核磁共振掃描儀等（延長其使用壽命）


High speed packaging 高速包裝

Plastics 塑料
Extruders, multilayer film 擠出機，多層薄膜


Pharmaceutical 製藥

Automotive 汽車

Painting, robots, sags caused by welders 塗漆，機器人，焊接造成壓降
Printing 印刷

© ABB Group
April 13, 2015 | Slide 6
Chemical 化工




setup time missed deadlines 重新啓動機器浪費時間，延遲交期
Home
Cause of Power Quality Problems 電力品質問題的起因

The Utility attempts to supply sag and swell free power to the end user. However even with
extensive maintenance programs the Utility cannot prevent power quality problems from
affecting the end user.
盡管台電耗費許多人力和大筆金錢維護電力網路，嘗試提供穏定電壓給用戶。仍無法避免電力品
質問題造成用戶的困擾。

Some Causes of PQ problems 電力品質問題的產生原因



© ABB Group
April 13, 2015 | Slide 7
Weather related events 天氣事件

Lightning 閃電

Heavy rain 暴雨，Snow 下雪

High wind 大風，Typhoon 颱風

Earthquake 地震
Single Phase Sags the most common PQ event
單相壓降是最常見的電力品質事件
Accidents 偶發事件

Vehicle 車禍

Construction, cranes, excavation 建築施工，起重機，開鑿機

Human error 人為失誤

Animals in contact with lines 動物誤觸
Other 其它

Large motors starting 大電動機啓動

Short-circuit faults 短路故障

Switching operations 線路切換

Distribution equipment failure 配電裝置故障
Home
PCS100 AVC
Active Voltage Conditioner
Overview
© ABB Group
April 13, 2015 | Slide 8
Overview
PCS100 AVC specifications 40% type
© ABB Group
April 13, 2015 | Slide 9

Full correction, three-phase sags down to 60% retained voltage

Full correction, single-phase sags down to 40% retained voltage

Partial correction, three-phase sags down to 30% retained
voltage

Partial correction single-phase sags down to 0% retained voltage

Continuous “ONLINE” regulation

Over and under voltage regulation

Correction for voltage vector phase angle errors created by faults
in the supply

Voltage unbalance correction
Overview
PCS100 AVC features
© ABB Group
April 13, 2015 | Slide 10

Fast (sub-cyclic) response

Simple user controls

Rugged overload capability

Short circuit protected

Extensive diagnostics

Fault log

Voltage event data logging

Ethernet connectivity

Modular construction
Overview
Modular construction
© ABB Group
April 13, 2015 | Slide 11

Minimum spares required

High commonality of parts

Fast replacement
Overview
Single line diagram
Input
Sag/swell animation
3ph utility
supply
3ph output
secondary
Distribution
transformer
primary
Input
circuit
br eaker
Boost
transformer
Bypass
Auto
transformer
(non 400/480V
supply )
Rectifier and inverter
Environmental
System wiring diagram
© ABB Group
April 13, 2015 | Slide 12
Rectifier fuse
Load
Overview
Typical factory configuration
PCS100
AVC
The PCS100 AVC protects UPS
operation and gives extended
battery life
© ABB Group
April 13, 2015 | Slide 13
UPS
Overview
Full web and plant system
USB interface
USB port
Technician
commissioning
support tool
Resident webpage in
graphic display module
Plant SCADA
accessing data registers
Modbus/TCPIP
over Ethernet
Plant wide access from
web browser
Firewall
© ABB Group
April 13, 2015 | Slide 14
Worldwide web
10 Years of SAG Data
© ABB Group
10 Year Data from A Major Semiconductor FAB
Percent of nominal voltage
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
1
10
100
Duration Cycles
© ABB Group
April 13, 2015 | Slide 16
1000
40 % PCS100 AVC Response To The Events
Percent of nominal voltage
100%
90%
≥ 45% full
correction
80%
70%
60%
50%
40%
30%
20%
10%
0%
1
10
100
Duration Cycles
© ABB Group
April 13, 2015 | Slide 17
1000
40 % PCS100 AVC Response To The Events
Percent of nominal voltage
100%
90%
80%
70%
60%
50%
40%
30%
0 to 45%
partial
correction
20%
10%
0%
1
10
100
Duration Cycles
© ABB Group
April 13, 2015 | Slide 18
1000
PCS100 AVC
Case studies
© ABB Group
April 13, 2015 | Slide 19
PCS100 AVC
Case studies
© ABB Group
April 13, 2015 | Slide 20
1.
Bottling plant
Florida USA
2.
Plastic extruder
Auckland New Zealand
3.
Solar panel manufacturer
Maryland USA
4.
Semiconductor FAB
China/Korea
5.
DWA welding machine
Malaysia
6.
Printing press
USA
7.
Container crane
Hong Kong
Case study : four
Semiconductor FAB plants
© ABB Group
April 13, 2015 | Slide 21
Case study : four
Overview – reference clients (Electronics)
Over 350MW of voltage conditioners supplied to semiconductor FABs
in Asia and North America over the last three years
© ABB Group
April 13, 2015 | Slide 22
Case study : four
Major projects PCS100 AVC
Hynix Wuxi China






80 x 1000kVA, 1250kVA, 1500kVA
108MVA total
Supplied as three separate projects
Project 1
2006
Project 2
2007
Project 3
Commissioned May 2008
Hynix M11 Cheongju Korea
© ABB Group
April 13, 2015 | Slide 23

52 x 1250kVA, 1500kVA

Commissioned Feb 2008

Space allocated for M12
© ABB Group
April 13, 2015 | Slide 24
PCS100 AVC
System
© ABB Group
April 13, 2015 | Slide 25
PCS100 AVC
Rectifier
Sine Filter
IGBT
+ Bus
Fuses
L1
L2
L3
RFI
Filter
- Bus
Soft Start
Contactors
Back
© ABB Group
April 13, 2015 | Slide 26
Inverter

IGBT active rectifier

Bi-directional power flow

Sinusoidal input current

DC output
PCS100 AVC
Inverter
Fuses
+ Bus
IGBT
Sine Filter
Fuses
U
V
W
RFI
Filter
- Bus
SCR/Contactor
BYPASS
Back
© ABB Group
April 13, 2015 | Slide 27

IGBT inverter

Bi-directional power flow

Sinusoidal output current

DC input
PCS100 AVC
Injection transformer
Back
© ABB Group
April 13, 2015 | Slide 28
400kVA 480 volt model
Boost Transformer Internally Bypassed

When the AVC is not online the boost transformer primary must be short
circuited

Online means the AVC is running providing voltage regulation and sag
correction

When internally bypassed the boost transformer “from an electrical
perspective” appears as a reactor (inductor) in series with the load

Typical Internal bypass Impedance <2.5%

Some internal bypass event causes
Secondary
Supply
Load
Primary

Operator stopping AVC

Overload >150% for 30 seconds

Internal Fault
Equivalent electrical circuit for an
internally bypassed AVC
Primary Short
Circuited
Supply
INDEX
© ABB Group
April 13, 2015 | Slide 29
Load
PCS100 AVC
40% 3 phase balanced event performance graph
AVC Output Voltage
(Line to Line)*
120%
110%
100%
AVC Output
Voltage
Utility
Voltage
90%
AVC
Correction
time (s)
90s
80%
80s
70%
70s
60%
AVC in Bypass
60s
AVC Online
50%
50s
40%
40s
30s
30%
Correction
Time
20%
20s
10%
10s
600ms
0%
10%
70% balanced sag
20%
30%
40%
0s
50%
60%
70%
80%
90% 100% 110% 120%
Utility Voltage (Line to Line)
0340-712a
*AVC output at 0.8 PF for 208 volt systems
© ABB Group
April 13, 2015 | Slide 30
OPEX AVC and Dual Conversion UPS
800kVA 100% Load

kWhr at $2 NT

Chiller System COP 3

800kVA 480V System 800kVA Load
100% Load
AVC
Efficiency
UPS
AVC
Difference
98.70%
93.40%
5.30%
91,104 kW
462,528 kW
371,424 kW
NT$182,208
NT$925,056
NT$742,848
kW Input
30,368 kW
154,176 kW
123,808 kW
OPEX
NT$60,736
NT$308,352
NT$247,616
kW Losses
OPEX
Air Conditioning
OPEX Saving
One Year
NT$990,464
© ABB Group
April 13, 2015 | Slide 31
YEARS
5
NT$4,952,320
10
NT$9,904,640
15
NT$14,856,960
UPS
© ABB Group
April 13, 2015 | Slide 32
Thomas Liu 劉佳炘, PE Power Quality, 18/10/2012
PCS100 UPS-I, Industrial UPS
Short term outage protection
© ABB Group
April 13, 2015 | Slide 33
PCS100 UPS-I, Industrial UPS
There is a solution
© ABB Group
April 13, 2015 | Slide 34

The PCS100 UPS-I is the ideal solution
where very deep sags or short term
power outages are a problem

The PCS100 UPS-I uses energy
storage coupled through an inverter to
allow the downstream load to ride
through very deep sags and short term
outages

The PCS100 UPS-I is an offline system.
It is inactive unless the voltage falls by
10% - 13%. This enables it to be very
efficient, up to 99%
PCS100 UPS-I, Industrial UPS
Single line diagram
Input
Output
UPS-I Applied Voltage
Failsafe
Bypass
secondary
Utilit
y
Distribution
Transformer
Utility
Disconnect
Coupling
Transformer
primary
Inverter
Charger
Battery
Option
Ultra
Capacitors
UPS-I
© ABB Group
April 13, 2015 | Slide 35
Protected
Load
PCS100 UPS-I, Industrial UPS
Outage protection
Utility
Sag
Distribution
Transformer
Utility
Disconnect
Coupling
Transformer
Inverter
Ultra Capacitor
UPS-I
© ABB Group
April 13, 2015 | Slide 36
PCS100 UPS-I, Industrial UPS
Operation cycle
1. Utility voltage within limits
Power
to the load is supplied from the Utility

Energy flow
SCR’s On

Utility voltage



Output voltage
Inverter Off

UPS-I voltage
3. Utility returns
2. Utility Outage Occurs

Power to the load is switched to the UPI-I energy storage within ¼ cycle.
SCR’s
Off


Utility voltage



Energy
flow
Inverter on

© ABB Group
April 13, 2015 | Slide 37
Output voltage
UPS-I voltage
PCS100 UPS-I, Industrial UPS
Response to supply loss

PCS100 UPS-I Input

PCS100 UPS-I Output
© ABB Group
April 13, 2015 | Slide 38

On detecting a disturbance the inverter takes over the load by actively
commutating (turning off) the Utility Disconnect SCR switch

Transfer takes place in less than 1/4 cycle
PCS100 UPS-I, Industrial UPS
Energy storage – ultra capacitors
Ultra capacitors

Protection for 3 seconds (Typical)

Single string rating 300kW for 1 sec or
240kW (300kVA at 0.8 pf) for 3 sec

Ultra capacitors by LS Mtron, Korea

Design Life: 10 years

Cycle life: >500,000

24 pieces of 32V blocks per string (single or
double string enclosures)

+/- 375Vdc

High discharge efficiency

Safe and compact matching cabinet
User benefits
Double String Enclosure
© ABB Group
April 13, 2015 | Slide 39

Reduced maintenance

Smaller footprint
PCS100 UPS-I, Industrial UPS
Graphic display module
Status Page
online
On/Off
button
status bar
Menu
selection
buttons
Supply
voltage
Load
voltage
Load
current
Storage
voltage

Status Page
In bypass
© ABB Group
April 13, 2015 | Slide 40
Visual representation of the
PCS100 UPS-I components
PCS100 UPS-I, Industrial UPS
Graphic display module
Event & fault log

Event and Fault Log, date
and time stamped

Records over 5000 events

Log can be download to a
PC and viewed in Excel

Summary of power quality
events
Event summary
© ABB Group
April 13, 2015 | Slide 41
OPEX UPS-I and Dual Conversion UPS
800kVA 100% Load



UPS-I
kWhr at $2 NT
Chiller System COP 3
800kVA 480V System 800kVA Load
100% Load
Efficiency
UPS-I
UPS
Difference
99.30%
93.40%
5.90%
kW Losses
49,056 kW
462,528 kW
413,472 kW
Cost
NT$98,112
NT$925,056
NT$826,944
kW Input
16,352 kW
154,176 kW
137,824 kW
Cost
NT$32,704
NT$308,352
NT$275,648
Air Conditioning
OPEX Saving
One Year
NT$1,102,592
© ABB Group
April 13, 2015 | Slide 42
YEARS
5
10
15
NT$5,512,960
NT$11,025,920
NT$16,538,880
UPS
© ABB Group
April 13, 2015 | Slide 43
ABB PowerWave UPS 1kVA to 5.0MVA
10 November 2011
Newave SA
44
ABB PowerWave UPS 1kVA to 5.0MVA
General Data
DPA UPScale
Powerwave 33
Power range
10/20/40/80/120kW
60/80/100/120/160/200/2
50/300/400/500 kW
Output power factor
1.0
1.0
Parallel configuration
© ABB Group
April 13, 2015 | Slide 45
Up to 10 units
Efficiency
Up to 95.5%
Up to 96%
Input frequency
35-70Hz
35-70Hz
Input distortion THDi
<3% at 100%
<3.5% at 100%
Modular (Three phase)
Standalone (Three phase)
ABB PowerWave UPS Reference
10 November 2011
ABB PowerWave UPS Feature

Efficiency
full load (up to 96% in double conversion
online mode).

Low input current total harmonic
distortion(THDi)
(3.5% at 100% load)

Near-to-unity input power factor

Fully rated output power (PF=1)

DPA UPScales :

Capacity in 10KW or 20KW power steps

N+1 redundancy

Up to 95.5 efficiency

Low input harmonics distortion (THID <3%)

DPA – high level of flexibility

DPA – lowest total cost of ownership

DPA – maximum availability
© ABB Group
April 13, 2015 | Slide 48